Project: ElectricXenos   -  
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Builder Name:Timothy Drager   -  
Project:   Electric motor   -   VIEW REPORTS
Total Hours:583
Total Flight Time:
Total Expense:$122553.00
Start/Last Date:Aug 30, 2021 - Aug 30, 2023
Engine:Zero DSR
Propeller:PTip
Panel:FALKEN AVIONICS , FLIGHTVIEW EFIS FLIGHTBOX PRO, AIR DATA
 
Friendly URL: https://eaabuilderslog.org?s=ElectricXenos

Home or Last Project Picture

Apr 30, 2024     Delay in installing Aileron push rods - (12 hours)       Category: Wings
Not only is the depiction of the aileron push rod fasteners and bearings inconsistent, but it's missing parts and clear instructions.

I spent days racking my brain on how to resolve this. So I went to EAA CHAPTER 1250 INC and asked the experts. They gave me enough to resolve the problem in that the flanged sintered bronze flanged and thrust bearings supplied with a kit was too short to fit in the rod end, so I had to manufacture a small bushing to take up the slack in the rod end.

This has halted the project for weeks. The photo shows a solution that will provide adequate bearing surface using centered bronze bearings.

These bearings will be soaked with turbine oil prior to installation. I'm using turbine oil because Symmco recommends saturating the bearings in R&O 100 turbine oil.


 
Apr 10, 2024     Drilled holes left aileron wing hinge.       Category: Wings
Drilled holes left aileron wing hinge.


 
Apr 08, 2024     Aileron Hinge Drilling - (1 hour) Category: Wings
Continued drilling left hinge, using clamps to hold it in position.
 
Apr 05, 2024     Positioned left aileron on wing - (4 hours) Category: Wings
Progress:
- Riveted right aileron 118 places
- Final positioning of left aileron wing hinge, held on with 20 clamps
- Drilled 15 pilot holes. 103 to go
 
Apr 01, 2024     Drilled right aileron wing hinge - (2 hours)       Category: Wings
Right Aileron work completed:
- Drilled and installed one cotter on inner hinge
- Cut one 19.5 inch hinge pin
- Drilled and clecoed 1/8 holes in wing hinge
- Re-checked hole location for outer hinge cotter pin


 
Mar 26, 2024     Located holes for right aileron hinge cotter pin - (2 hours) Category: Wings
Located two holes by:
- Studying the drawings
- Understanding the design
- Measuring the angles
- Marking the hinge
 
Mar 24, 2024     Aileron right hinge mated - (4 hours)       Category: Wings
Aligned, mated and drilled right aileron wing hinge. Clecoed and mated the aileron and installed pin for a trial fit. Works well so far.


 
Mar 23, 2024     Aileron push rods and wing hinge - (5 hours)       Category: Wings
Getting ready to drill the right aileron hinge by:

Locating the drawings and understanding the correct dimensions
Measuring and cutting the wing hinges
Drawing locator marks on the wing hinge and wing
Clamping it in place.


 
Mar 22, 2024     Ailerons Done - (8 hours)       Category: Wings
Completed riveting both ailerons. This included a lot of drilling, clecoing, deburring, cleaning, reassembling, re-clecoing and riveting.

The results are strong and light. The light in the photo amplifies the fact the skin is dimpled where the ribs are riveted. For future reference, I would have, just to be sure measured and adjusted the bend angle of the ribs with a sheet metal tool and a square.


 
Mar 14, 2024     Ailerons getting done - (2 hours) Category: Wings
Left aileron complete, including drilling and riveting. Right aileron 70% drilled, including hinge.
 
Mar 10, 2024     Build Right Aileron - (8 hours) Category: Wings
Drilled all ribs, drilled inboard hinge. Made outboard hinge.
 
Feb 24, 2024     Left aileron ribs and hinge - (8 hours)       Category: Wings
Left aileron drilled and clecoed, including the hinge.


 
May 04, 2023     MOVED - BOXES AND BOXES - (50 hours)       Category: Workshop
Got married to the love of my life. Moved into her farm. All workshop tools moved. Unpacking now.


 
Oct 19, 2022     Inventory - (3 hours) Category: Research
Inventoried all kit parts. All complete except for a few minor items.
 
Oct 01, 2022     Fuselage inside workshop - (5 hours)       Category: Workshop
The main fuselage of a Sonex is 40 inches. The workshop door needed 42 inches to clear not only the fuselage, but the latch and exterior aluminum L brackets.
I removed the pre-hung door and two 2x6 studs surrounding it. Viola: 42 inches.

Started inventory of all parts.


 
Sep 20, 2022     DELIVERY DAY - (3 hours)       Category: Workshop
Delivery day for the quick build kit!

It was a cluster bomb because:
- 18 wheeler got stuck approaching the house
- 18 wheeler could not get into the 400ft driveway, necessitating 5 trips up and down the driveway with a trailer
- rained
- police
- blocked school buses

First-world problems…
The good news is that the parts were safely delivered…no injury to people or airplane.


 
Mar 24, 2022     ASSEMBLED LEFT STAB FRAME - (2 hours) Category: Tail Feathers
Finished deburing left stab skin. Cleaned all parts. Began cleco of frame.
 
Mar 12, 2022     DEBURR - (3 hours) Category: Tail Feathers
Deburred left stabilator.
 
Feb 27, 2022     DISASSEMBLED LEFT STABILATOR - (1 hour) Category: Tail Feathers
Removed all clecos. Getting ready for deburring.
 
Feb 25, 2022     DRILL LEFT STABILATOR TOP SIDE - (3 hours)       Category: Tail Feathers
- Drilled 50 #30 holes
- Went to the EAA workshop and borrowed some #30 clecos


 
Feb 24, 2022     DRILLED - (4 hours)       Category: Tail Feathers
- Drilled #30 holes in lower left stabilator


 
Feb 22, 2022     PILOT DRILLED LEFT STABILATOR - (4 hours)       Category: Tail Feathers
- Turned over stabilator
- Clamped and strapped bottom stabilator
- Drilled and clecoed stabilator
- Next: Final drill all holes


 
Feb 22, 2022     STARTED LOWER SKIN FITMENT IN LEFT STABILATOR - (2 hours)       Category: Tail Feathers
- drilled 40 pilot holes in upper skin
- flipped over the stabilator
- corrected design defect in outer rib nose, which caused deformation in skin leading edge
- clamped down lower skin


 
Feb 18, 2022     STARTED SKINNING LEFT STABILATOR - (6 hours)       Category: Tail Feathers
Squared up the frame with:
- Big square, 18x24 inch
- Skin. It is perfectly square

Then clampled in:
- Square
- Skin
- Hinge
- Rear end of ribs

Checked alignment of primary datum at:
-Rear end of skin with rear spar
- Hinge with end of rear spar
- 75 inches of rear end of spar with skin and hinge
- Spar drill lines with pilot holes in skin

Once squareness and alignment was checked, pilot drilled:
- Rear spar and hinge using skin pilot holes
- Ribs


 
Feb 17, 2022     DRILLED, SQUARED AND MARKED REAR SPAR - (4 hours)       Category: Tail Feathers
- Marked rear spar pilot hole locations
- Drilled rear spar on mini-mill
- Marked hole alignment lines on spars
- Squared assembly with big square
- Clamped frame with mini-clamps


 
Feb 16, 2022     TRIMMED AND MEASURED REAR STABILATOR SPAR - (4 hours)       Category: Tail Feathers
- Assembled left stabilator frame
- Realized I must pilot drill rear spar


 
Feb 15, 2022     STARTED FINAL ASSEMBLY OF LEFT STABILATOR - (2 hours)       Category: Tail Feathers
Waiting on the pitot static probe adapter so I can make the holder plate, so I:
- Closed up right stabilator skin and placed it in the loft
- Started final assembly of the left stabilator starting with tightning two AN3 bolts


 
Feb 14, 2022     PREPARING FOR CLOSING UP STABILATOR FOR RIVETING - (5 hours)       Category: Tail Feathers
- Riveted front spar to ribs
- Countersunk 8 rear spar and rib holes
- Riveted all rear spar to ribs
- Ran three aluminum pitot-static-total energy probe lines


 
Feb 13, 2022     DEBURRED RIGHT STABILATOR - (4 hours)       Category: Tail Feathers
Today I;
- Cleaned all parts with acetone
- Installed close tolerance bolts
- Drilled and installed six oversize rivets in rear clip
- Deburred all holes
- Reassembled frame
- Clecoed top skin
- Ground down dimple tool due to interference


 
Feb 11, 2022     DIMPLE TEST PASSED - (3 hours)       Category: Tail Feathers
I dimpled two scraps and the rivet pulled better than expected. See photos. The enlargement was minimal because I hypothesize that the 120 degree angle makes for minimal dimple depth.


 
Feb 09, 2022     DRILLED ALL FINAL HOLES IN RIGHT STABILATOR - (4 hours)       Category: Tail Feathers
Drilled final holes #30 in right bottom skin and all ribs.


 
Feb 08, 2022     SKINNED RIGHT STABILATOR - (5 hours)       Category: Tail Feathers
Completed:
- Fitted lower skin using 2x2 wood clamped over main spar, then one ratcheting strap near end of stabilator
- Resolved minor skin wrinkling in two places where front ribs interfered with skin by trimming the front of the ribs by 1/8 inch.
- Drilled all pilot holes using pre-drilled skin holes.
- Drilled bottom skin holes with #40 final size


 
Feb 07, 2022     FINISHED DRILLING TOP RIGHT STABILATOR - (6 hours)       Category: Tail Feathers
Drilled all pilot holes including:
- spars
- ribs
- hinge

Ruddervator, hinge and tip fits fine so far.

Flipped it over, strapped it down and analyzed bottom hole locations. They don't line up well. Will continue analyzing tomorrow.


 
Feb 06, 2022     SKINNING RIGHT STABILATOR - (4 hours)       Category: Tail Feathers
Squared stabilator frame with big square and skin. Skin is perfectly square.
Pushed ribs in place.
Drilled all ribs except root rib. Will do that tomorrow.


 
Feb 04, 2022     FRAME AND SKIN HOLE LOCATION - (10 hours)       Category: Tail Feathers
- Drilled pilot holes in rear rib to spar interface,
after analyzing plans and all angles.
- Layed skin onto frame and began pilot hole fitting.


 
Feb 02, 2022     BREAKTHROUGH - (4 hours)       Category: Tail Feathers
Yes, I CAN PROCEED with assembling the skin, stabilator with rear spar, ruddervator hinge and tip nut plates.

KEY FINDING: Only the root rib rivets are held for the final mating of the stabilator and Y. The other rivets are either flush or don't interfere with the rear spar cap.

See photo: After actually reading and UNDERSTANDING the drawings a lightbulb went on.


 
Jan 31, 2022     REMADE LEFT ROOT RIB - (1 hour)       Category: Tail Feathers
First attempt had pilot holes too close to the edge.


 
Jan 29, 2022     JUMPING COMM RADIO FREQUENCY - (2 hours)       Category: Engine
The FlightBox Pro arrived with v3 software upgrade. Testing revealed:
- XPDR seems to work
- COMM radio frequencies displays random numbers, rendering it useless
- Bug reported to Steve Sokol
See: https://youtu.be/wOw7YcTaboI


 
Jan 29, 2022     Understanding Redrive System - (2 hours)       Category: Engine
Got a call from Gabriel Devault, inventor of the Zaero redrive. During and after the discussion, the following points were revealed:

Bearing maintenance
Q: How long do the bearings last?
A: Three answers:
1. Recommended replacement of Zaero and motor bearings at 1000 hours.
2. Preflight and annual / 100 hour inspection item: Listen and feel for growling or other unusual noises like high and low frequently rumblings or thumping from redrive system including two redrive bearings and Zero motorcycle motor bearings.
3. The SKF bearings used in Zaero and motor are identical. A bearing calculators was used to validate loads in this application. See photo below of a calculator.
The Zero motor controller monitors temperature and displays warnings to pilot. For the Zaero I suggested pointing an infrared temperature sensor at the hub housing the two bearings and displaying to pilot in flight.


 
Jan 28, 2022     Recalibrated my plans reading knowledge, cut rear spar - (5 hours) Category: Tail Feathers
Recalibrated my plans reading knowledge: double lines are front view. This means:
- Reviewed photos of other build websites
- My right and left spars were reversed
- Re-marked all spars and ribs

Cut right rear spar per plan.
 
Jan 27, 2022     Received, unpacked and inspected Zaero Redrive kit - (3 hours)       Category: Engine
MAJOR PROGRESS
Received, unpacked and inspected Zaero Redrive kit

Sent Email to Flit LLC:
SUMMARY: Send a throttle, main sprocket and sprocket retainer.

DETAILS:
I am ecstatic about receiving the Zaero kit. Thanks for installing the bearings.

A little waxing philosophical, if you will: In this life, after everything is stripped away, all you have is your reputation. The Zaero kit has a stellar reputation as far as concept and design. May I make several suggestions?

- Communication
- Quality control

COMMUNICATION
1) Delivery
The original delivery estimate was 12 weeks. Actual was 20 weeks.
For a prototype, the delivery time was acceptable, but resetting expectations should be done early in the process. Being a pilot trained in worst-case analysis, I thought my Zaero investment might be a total loss because of the loss of communication.

2) Instruction
There were extra cables and one bolt included in the kit that I don't understand. A parts list and assembly diagram would aid in understanding:
- Spare bearings. Bearing orientation. Pressing technique.
- Mounting bolts to buy
- Washer type and quantity
- Belt tension and XYZ adjustment points
- Torque specs
Maybe I can help you make such an instruction sheet, once I figure it out. LOL

QUALITY
3) Missing throttle. See photos. Please send one.
4) Damage in shipping. Packaging was inadequate to prevent damage. See photos. Please send two new parts to replace:

- damaged main sprocket
- dented belt retainer on small sprocket
- scraped and chipped paint and metal on mount. Just let me know what alloy was used and I'll file the burrs and re-paint.


 
Jan 27, 2022     Prepared right rear spar - (3 hours) Category: Tail Feathers
- Received and unpacked replacement 49 inch spars from Sonex
- Straightened to 90 degrees
- Measured and began cutting to plans
 
Jan 18, 2022     Filler rib in stabilator tips - (5 hours)       Category: Tail Feathers
Filler rib in stabilator tips:

- Measured hole location
- Drilled pilot and final holes
- Deburred 10 holes
- Riveted


 
Jan 17, 2022     Ordered Prince P-Tip propeller - (2 hours)       Category: Propeller
Ordered Prince P-Tip propeller, and custom paint job. Zaero redrive kit has been boxed.


 
Jan 17, 2022     Cut tips, squared ribs, Drilled inner front rib - (6 hours)       Category: Tail Feathers
Cut tips with cutoff wheel
Squared ribs and spar with sheet metal former
Drilled inner front rib


 
 
Jan 13, 2022     Drilled and deburred spar holes - (2 hours) Category: Tail Feathers
Drilled and deburred spar holes. Cleaned and ready for riveting.
 
Jan 12, 2022     Drilled front spar and ribs - (6 hours)       Category: Tail Feathers
Pilot Drilled:
- front spar
- front of ribs
Final drilled #30 spar cap 5%


 
Jan 11, 2022     Began drilling and clecoing ribs on left stabilator - (6 hours)       Category: Tail Feathers
Began drilling and clecoing ribs on left stabilator:
- Squaring rib
- Measuring stabilator dimensions
- Clamping


 
Jan 10, 2022     Drilled and rough build of left stabilator - (6 hours)       Category: Tail Feathers
Drilled 3/8 inch root spar holes for stabilator.
Drilled clips.
Rough assembled ribs to spar and clamped in place.


 
Jan 09, 2022     Drilled pilot holes through left spar and cap       Category: Tail Feathers
Still waiting for Sonex to send me the rear 49 inch spar channel, so I pilot drilled the holes through left spar and cap.


 
Jan 09, 2022     Re-made aft clip - (1 hour) Category: Tail Feathers
Re-made aft clip by:

- Cutting
- Bending
- Drilling
 
Jan 07, 2022     Drilled and Clecoed right front side stabilator ribs - (7 hours)       Category: Tail Feathers
Squared all ribs. Drilled pilot holes. Clecoed front side ribs to spar. Waiting for Sonex to ship the rear spar channel. They were closed for two weeks for holiday shut down.

Re-made rear left clip, drilled and bent to 95.1 degrees.


 
Jan 06, 2022     Drilled and clecoed rear clip - (3 hours)       Category: Tail Feathers
Drilled and clecoed rear clip onto rib -12. Indexed and squared rib -11. The 76 degree bend was twisted, so I will correct it.


 
Jan 05, 2022     Assembling right stabilator - (7 hours) Category: Tail Feathers
Placed spar on jig.
Clamped most ribs on spar.
Verified angles in 20 places: 95.1 degrees on root rib and 90 degrees on all other angles.
 
Jan 04, 2022     Analyzed squareness of build bench - (2 hours) Category: Workshop
Went flying in my Cessna 172, then:

- organized the work bench
- analyzed squareness of aluminum work bench

I need to square the stabilator spar cap, tabs and ribs.
 
Jan 03, 2022     Installed shop air and vice - (7 hours)       Category: Workshop
Procured and installed shop air and vice.


 
Jan 03, 2022     Rearranged workshop - (4 hours)       Category: Workshop
Installed two cabinets
Installed 1971 stereo from my parents. Played vinyl LP American Pie.
Installed air compressor
Cleaned up pegboard mounting pegs


 
Jan 01, 2022     Ordered Pitot Static / Total Energy System - (2 hours)       Category: Avionics
Items Qty Subtotal
ESA Systems Multi-Probe MNI/UN

SKU: 4587, 4590A, 4596C-Carbon Fiber - SKU 4596C

Select Type:
MU1004 MNIC/UN Carbon Fiber - SKU 4596C
Options:
Probe Protective Pouch MNIC/UC - SKU 4632
1 $324.00
ESA Systems Probe Mounting Adapter

SKU: 4561, 4564, 4603, 4604, 4610, 4620, 4621, 4630-4603

Select Type:
UN (AD1002) - 4603
1 $150.00
ESA Systems ZU1001 Spacer Sleeve

SKU: 4622

1 $3.00
ESA Systems O-Ring

SKU: 4534, 4537, 4540, 4544, 4545

Select O-Ring Size:
ZU1003 Set Mounting Adapter for US, SUN, UNG - SKU 4545
1 $3.00
Subtotal $480.00
Shipping & Handling $27.75
Estimated Total $507.75


Tygon Aab00011 Tubing,3/16 I.D.,50 Ft.,Clear,Flexible

Product
6061T6 ANGLE 2X2X1/8 1FT
Part #: 03-48400-1
Mfr Part #:

$3.950 / EA
Quantity
1.00 $3.95
Product
BARGAIN BAG OF ALUMINUM
Part #: 03-40100
Mfr Part #:

$14.950 / EA
Quantity
1.00 $14.95
Product
CLOSE TOLERANCE BOLT AN173-5 (PACK OF 5)
Part #: AN173-5-5
Mfr Part #: 03547-5

$4.085 / EA
Quantity
1.00 $4.09
Product
2024T3 BAR 1/2" X 6" 1FT
Part #: 03-56000-1
Mfr Part #:

$40.500 / EA
Quantity
1.00 $40.50
Product
3003-0 TUBE 3/16" OD X .028" W
Part #: 03-40300
Mfr Part #: 500FT COIL

$0.350 / FT-20.0%
Net $0.280 Quantity
50.00 $14.00
Product
ELASTIC GROMMET AN931-3-5
Part #: AN931-3-5
Mfr Part #: MR-200-0548

$0.230 / PC


 
Jan 01, 2022     Drilled caps - (6 hours)       Category: Tail Feathers
Drilled caps with pilot and 1/8 drill bits. Deburred all holes.


 
Dec 31, 2021     Drilled right caps and clips - (6 hours)       Category: Avionics
Drilled right caps and clips using both hand drill and mill.


 
Dec 31, 2021     Debugged XPDR Offline Error - (2 hours)       Category: Avionics
Error message XPDR OFFLINE.

Trig COMM radio TN92, ADC, Flightbox Pro work fine.

Grounded pin 13 (XPDR Enable) on Trig TT22 - no joy.

Checked all power, ground and connectors - all good. Power is 13.9 VDC.

XPDR has 0Hz data rate.


 
Dec 31, 2021     Analyzed XPDR non-function issue       Category: Avionics
I believe the XPDR is not functioning because I need to connect the Power ON pin (13) to a ground pin to get the transponder to power up. This can simply be a permanent link from pin 13 to one of the ground pins or it can be through a switch on the panel. Be careful here – the Power ON pin is NOT the same as the Controller Power pin. If you connect Controller Power to ground you create a dead short. (All other pins on the DB-25 as per the Trig documents.)


 
Dec 31, 2021     Drilled caps and spar - (6 hours)       Category: Tail Feathers
Using the pre-drilled Sonex spar as a template, drilled the main cap and spar.


 
Dec 29, 2021     Drilled 8 pilot holes in spar cap. - (4 hours) Category: Tail Feathers
Analyzed plans. Drilled 8 pilot holes in spar cap.
 
Dec 28, 2021     Successful avionics test - (5 hours)       Category: Avionics
- Made COMM coax cable with TNC and BNC connectors using RG400 coax
- Connected power to Flightbox
- Inserted five 5 amp fuses
- Connected 13VDC power supply
- Configured Flightview Wifi and app
- Verified all radio functionality. Passed.
- Will test magnetometer next.


 
Dec 27, 2021     Spars - (7 hours) Category: Tail Feathers
Made spars
Need to buy two more spar's worth of material due to my mismanagement of raw materials.
Analyzing main spar assembly process
 
Dec 26, 2021     Clips and Ribs - (6 hours) Category: Tail Feathers
Made root ribs and clips.
 
Dec 23, 2021     Root clips - (4 hours)       Category: Tail Feathers
Deburred 30 holes in ribs.
Chamfered root clips
Made LARG root clip


 
Dec 22, 2021     Drilled ribs - (3 hours)       Category: Tail Feathers
Re-made one rib
Drilled ribs.


 
Dec 21, 2021     30% done with antenna test bench - (8 hours)       Category: Avionics
Mounted two of six antennas outside my home avionics work bench:

XPDR
Separation 3 feet from COMM antenna
Ground Plane 120mm
COAX RG400 or RG393

COMM
Separation 12 inches
Ground Plane 1 metre square
COAX RG400 or RG142B

Flightbox
Mount the ADS-B receiver antenna at least four (4) feet from transponder
Mount antenna in accordance with manufacturer's instructions

Fabricate or purchase a length of RG58 coaxial cable to run from the antenna to the FlightBox Pro.

Use a connector appropriate to the antenna (typically BNC) on the antenna end of the cable.

Use a male SMA connector on the splitter end of the cable.

Connect the antenna to the splitter using the cable.

Connect the splitter to the 1090 MHz output on the splitter to the 1090 MHz input on the FlightBox Pro using an SMA male / SMA male pigtail cable.

Connect the splitter to the 978 MHz output on the splitter to the 978 MHz input on the FlightBox Pro using an SMA male / SMA male pigtail cable.

TN72
not be mounted close to VHF COM transmitter antennas, and other antennas emitting high power


 
Dec 20, 2021     Completed ten ribs - (6 hours) Category: Tail Feathers
Completed the rest of the ten ribs. I may remake one since one of the flanges had to be re-bent to meet the drawing. It has ripples and machine marks.
 
Dec 19, 2021     Sorted the collets and mills - (1 hour) Category: Tools
Unboxed and sorted the collets, mills, parallels and clamp tooling.
 
Dec 19, 2021     Set up 25 pegboard hooks - (1 hour) Category: Workshop
Set up 25 pegboard hooks, mainly for mill tools : collets and mills.
 
Dec 17, 2021     Made four ribs - (6 hours) Category: Tail Feathers
My first rib was 1/8 inch too long. I re-bent the aluminum and brought the length in-spec. I will have Billy, our resident expert tell me if it's acceptable. I used the lesson learned and built three more ribs that are in-spec.
 
Dec 16, 2021     Installed Mill - (7 hours)       Category: Tools
Prepared area for mini-mill from LittleMachineShop.com.
Installed mill.
Tested mill for run-out.


 
Dec 15, 2021     First rib - (3 hours) Category: Tail Feathers
Studied plans, cut first rib and bent the 76 degree angle.
 
Dec 15, 2021     Started Spar and Clips - (5 hours)       Category: Tail Feathers
Analyzed plans for spar and clip members. Cut first 21 inch spar. Cut clips.


 
Dec 13, 2021     Assembled Test Radio Panel - (8 hours) Category: Avionics
Did four things:
1) Drilled and tapped holes for Adel clamps for wiring runs on 1.8 inch aluminum radio panel.
2) Connected power and grounds to XPDR, COMM and GPS
3) Mounted ADC and Flightview Pro close to exterior door. GPS receiver antennas will exit through a hole to daylight.
4) Analyzed RF cable, connector and antenna mounting requirements:
XPDR
Separation 3 feet from COMM antenna
Ground Plane 120mm
COAX RG400 or RG393

COMM
Separation 12 inches
Ground Plane 1 metre square
COAX RG400 or RG142B
 
Dec 12, 2021     Design layout - (4 hours)       Category: Avionics
Layed out the avionics. Trimmed some unneeded wires. Drilled and tapped #6-16 mounting screw holes for four boxes.


 
Dec 10, 2021     Erected five peg boards - (6 hours)       Category: Workshop
Erected five peg boards for tool organization.


 
Dec 09, 2021     Proposed avionics mounting - (2 hours)       Category: Avionics
What do you think of my proposal photo for mounting in my Sonex Xenos electric motor glider?
https://community.falkenavionics.com/t/aft-mounting-of-flightbox-pro/453/4
ADVANTAGES
1. Flightbox Pro - Square orientation.
2. ADC (Air Data Computer) - Magnetometer isolated from all electrics. Since this is an electric aircraft, I want the magnetometer isolated from the 50KW motor and electronics up front.
3. Hinge - Panel for XPDR, COM, GPS, Fuse box and USB Hub. Hinge swings down for easy maintenance.
4. Only two wires will run to the front of the Aircraft: 12 volt DC Power, 5.1 amps and PTT - Push to Talk switch
5. No messy wires - Headset jacks behind pilot.
6. Easy mounting of XPDR, COM and GPS antennas.
7. Good wifi signal to iPad.
8. Declutter instruments panel, for a Tesla-like look. ( Simple User Interface)


 
Dec 09, 2021     Installed table saw - (2 hours) Category: Workshop
Installed Craftsman table saw from Lowes.
 
Dec 09, 2021     Installed mini split heat pump - (8 hours)       Category: Workshop
Installed mini split heat pump, a Mitsubishi 9K, which can heat down to -13 degrees F. See https://youtu.be/51Zx1MJL3Qc


 
Dec 09, 2021     Bent thin hockey sticks - (3 hours) Category: Tail Feathers
Made a one-inch V block. Bent thin hockey sticks to 14.3 degrees with my new 12 ton press.
 
Dec 04, 2021     Finished 12 ton press - (1 hour) Category: Tools
Finished assembling 12 ton press by squaring the press and tightening all bolts
 
Dec 04, 2021     Made V block out of wood - (2 hours) Category: Tail Feathers
Made V block out of wood to make the next 14.3 degree angle bends.
 
Dec 03, 2021     Researched mounting of Flightview Pro - (2 hours) Category: Avionics
Searched the support sites on web. Determined to mount the Flightview Pro, which has the AHRS sensor, on top of the rear bulkhead.
 
Dec 03, 2021     Tightened bolts for hydraulic press Category: Tools
Tightened bolts for hydraulic press frame.
 
Dec 03, 2021     Hockey sticks bent - (3 hours) Category: Tail Feathers
Tweaked the twist and 14.3 degree angle of the stabilator spar caps using the vice.
 
Dec 02, 2021     Assembled press - (3 hours) Category: Tools
Bought and assembled a 12 ton press for future bends.
 
Nov 30, 2021     POWERED UP WORKSHOP - (6 hours)       Category: Workshop
Wired two breaker boxes for workshop 50amp service at 220VAC.


 
Nov 29, 2021     Installed 50Amp cable in garage - (5 hours) Category: Workshop
Placed and cemented PVC conduit and cable in garage. Will energize 50Amp service tomorrow. Contacted HVAC installer about installing a Mitsubishi 9K BTU heat pump, SEER 30.5
 
Nov 28, 2021     Completed power cable and conduit run to Garage - (4 hours) Category: Workshop
Placed and cemented PVC conduit and cable into trench from workshop to garage, where there is 200 Amp service. Inside garage work can commence tomorrow. 50Amp service will be installed.
 
Nov 27, 2021     Wire workshop - (16 hours) Category: Workshop
- Procured conduit, cable, fittings, breaker box
- Installed breaker box, 12 breakers
- Dug trench for conduit, 50% rock
- Installed 26 ft of cable in conduit
 
Nov 24, 2021     Adjusted hockey stick angle - (3 hours) Category: Tail Feathers
Plans call for 14.3 degree bend on the spar aft caps. I exceeded this by .5 degrees, so I put it in the vice and banged it with a wood block and sledge hammer, which brought the angle to exactly 14.3 degrees. However, there is up of .5 degrees of twist at the bend and plan on correct it with my vice and a mandrel tool to "untwist" the twist. The mandrel is a 2 ft adjustable wrench.
 
Nov 23, 2021     Completed Left Ruddervator and bent two pieces Category: Tail Feathers
Completed Left Ruddervator with rivets and bent two pieces to 14.3 degrees.
 
Nov 23, 2021     Modules, current and antennas - (5 hours)       Category: Avionics
Did three things for Falken Avionics package:
1) Current
Created a spreadsheet to sum all currents. 5.2 amps max
2) Layout
Laid out all modules on 1/8 aluminum sheet.
3) Antennas
Analyzed antenna and coax cable requirements. Need a UHF antenna for the Trig transponder / ADSB Out system.


 
Nov 21, 2021     Drilled Left Ruddervator - (4 hours)       Category: Tail Feathers
Measured, Marked, and pilot Drilled Left Ruddervator and it's hinge.


 
Nov 19, 2021     Marked and Cut left ruddervator hinge - (1 hour) Category: Tail Feathers
Marked and Cut left ruddervator hinge to make ready to drill.
 
Nov 17, 2021     Marked drill locations - (3 hours) Category: Tail Feathers
Marked drill hole locations for left hand side ruddervator.
 
Nov 16, 2021     Measured and cut left ruddervator - (5 hours) Category: Tail Feathers
Measured and cut left ruddervator diagonal horn control diagonal. Measured rib drill locations.
 
Nov 15, 2021     Right Ruddervator Complete - (8 hours)       Category: Tail Feathers
Drilled, deburred, cleaned, reassembled and riveted right ruddervator.


 
Nov 14, 2021     Drilled all pilot holes in right ruddervator - (5 hours)       Category: Tail Feathers
Drilled all pilot holes in right ruddervator, including the hinge.


 
Nov 14, 2021     Drilled pilot holes for two inner ribs - (2 hours) Category: Tail Feathers
Drilled pilot holes for two inner ribs in right ruddervator. Learning techniques for accurate and efficient drilling and deburring.
 
Nov 12, 2021     Measure and Cut Right Ruddervator - (7 hours) Category: Tail Feathers
Cut and trimmed right ruddervator, including four ribs and hinge. Measured and fit all pilot holes.
 
Nov 11, 2021     Initial layout. Ordered connector crimp tool - (4 hours) Category: Avionics
Laided out avionics preliminarily. Will all go behind the pilot. Ordered crimp tool and extractor for DB9 connector for Trig radios.
 
Nov 10, 2021     Drilled Hinge - (2 hours) Category: Tail Feathers
Finished drilling right hand side ruddervator hinge and prepared to cut the ruddervator with tin snips.
 
Nov 09, 2021     Drilled hinge - (4 hours)       Category: Tail Feathers
Made a jig to drill hinge. Drilled right side hinge.


 
Nov 08, 2021     Prepared Right Ruddervator Skin and Drive - (4 hours) Category: Tail Feathers
- one hour to figure out plans
- one hour to prep workbench for larger area required
- one hour to create perfectly flat work space
- one hour to measure and draw lines on skin
 
Nov 07, 2021     Assembled Left Hand Root Rib Assembly - (2 hours) Category: Tail Feathers
Assembled Right and Left Hand Root Rib Assembly with 120 degree countersink drill and rivets.
 
Nov 05, 2021     Bent Left Hand Root Rib Assembly - (1 hour) Category: Tail Feathers
Bent Left Hand Root Rib Assembly 15 degree angle using a vice. Checked with angle tool.
 
Nov 04, 2021     Ordered countersink drill bits - (2 hours)       Category: Tail Feathers
Ordered wrong countersink drill bits from McMaster since they were not:

- Self-centering
- Depth adjustable

So I went to Aircraft Spruce and found COUNTERSINK 120 DEGREE 5PC KIT, which includes #30 and 40 rivets, 120 degrees, for use in the self centering with depth gauge tool called MICRO - STOP COUNTERSINK CAGES.


 
Nov 03, 2021     Started building - (6 hours)       Category: Tail Feathers
Started building the Right Hand Root Rib Assembly, -02R. I Bent the Right Hand Root Rib, -05R, on a vice to 15 degrees. Drilled #40 holes, clecoed and drilled #30 holes. Stopped to order 120 degree countersink drill bits from Mcmaster.


 
Nov 02, 2021     More deburring - (4 hours)       Category: Tail Feathers
Despite placing the large tail structural parts on 8 inch the Scotch Bright wheel, tool marks from Sonex still were struck into the aluminum. They were very deep from Sonex. Between a file, sand paper and Dremel tool with Scotch bright wheels and pads the job is finished except for the skins. I wanted the metal to look relatively bright; not have a bunch of scratches. I don't want to remove too much material but need to determine if my present level of deburring is acceptable.


 
Oct 31, 2021     Deburring - (3 hours) Category: Tail Feathers
Deburred channel aluminum with Scotch Bright wheel.
 
Oct 29, 2021     Deburr more parts - (5 hours) Category: Tail Feathers
There were a lot of factory machining grooves that needed to be smoothed. 50% complete.
 
Oct 28, 2021     Avionics Arrived - (3 hours)       Category: Instrument Panel
Received avionics package and an iPad. Read installation manual. Designing panel.


 
Oct 28, 2021     Deburring Tail Kit - (1 hour)       Category: Tail Feathers
Received tail kit. Inventoried all parts. Started deburring all pieces in the box.


 
Oct 03, 2021     Started designing with Hangar Flying - (1 hour)       Category: Instrument Panel
Started designing instrument panel with Hangar Flying.


 
Oct 01, 2021     Parts Bins and Pegboard - (1 hour)       Category: Workshop
Small parts storage bins, shelves, hooks and pegboard.


 
Sep 29, 2021     Plan to use P-Tip Propeller - (1 hour)       Category: Propeller
The Prince P-Tip Propeller
P-TipThe P-TIP design The droop P-TIP is to control the air spillage over the propeller tip. It delays the tip vorticies which cause drag and turbulence within the propeller arc. A propeller, like a wing, works best when it has unturbulated air over the airfoil sections. The P-TIP delays the vorticies, the propeller then has smooth air to provide best thrust and a pronounced reduction in propeller noise.

RV with Carbon Fiber P-TipAn additional benefit of the P-TIP design is the volume of air the propeller produces. When air flows through a standard propeller, the airflow will "roll" over the propeller tip. As soon as it passes the tip it will tuck down behind the propeller blade giving a cone of air from the propeller smaller than the propeller diameter. For example, a 72" diameter propeller without a P-TIP will give a volume of air from the propeller of approximately 68" in diameter; a P-TIP propeller will provide 72" of air volume. This means that a 68" P-TIP will give the same volume of air as a standard tip 72" propeller.

Sonex with Carbon Fiber P-TipBy reducing propeller diameter there is less frontal area or flat plate drag on the aircraft. Higher top speeds are the result without sacrificing takeoff or climb.

Pitch change and the Scimitar shape
The propeller has a fixed pitch that relies on the forward pull of the propeller to automatically provide pitch change proportional to the amount of force being applied to the propeller disk. When a propeller operates at a slower airspeed than its maximum capability, it has a proportional pull in relation to the velocity of forward motion, so at takeoff and climb, the propeller will have its largest forward pull. Due to the scimitar shape, the tip of the propeller cones forward, as the coning angle changes the propeller will lessen pitch that provides shorter takeoffs and higher rates of climb. As the propeller increases in forward speed the disk pressure is reduced, this forces the propeller to increase pitch and top speed. This change in pitch is approximately four inches from takeoff to cruise.

See: https://www.princeaircraft.com/TheProp.aspx


 
 
Sep 28, 2021     Ordered tools Category: Tools
Ordered Belt sander, horizontal /vertical band saw w/bimetal blades, 4 sizes of clecos, cleco pliers, electric rivet puller.
 
Sep 28, 2021     Ordered Sonex Xenos B Quick Build kit - (20 hours) Category: Research
Ordered Sonex Xenos B Quick Build kit after discussion with Sonex at Airventure 2021.
 
Sep 28, 2021     Ordered electric redrive kit - (2 hours) Category: Engine
Ordered electric redrive kit from https://flitllc.com/
 
Sep 28, 2021     Bought Zero DSR Motorcycle - (10 hours) Category: Engine
New DSR will donate it's motor, battery and controller.
 
Sep 28, 2021     Discussed electric motor - (3 hours) Category: Research
Discussed electric motor system with Gabriel at https://flitllc.com/
 
Sep 28, 2021     Ordered 12x24 shed workshop - (8 hours)       Category: Workshop
Includes:
4 x 4 Pressure Treated Skids form the foundation Floor joists are standard 2 x 4's 8″ on center 3/4″ T&G SmartFinish Wood Flooring Walls are Standard with 2 x 4s 16″ OC 8′ High Walls ��rtside Siding Finishes the Exterior, 1-9 x 7 Solid Steel Garage Door w/ Aluminum Diamond Plate Guard (Note: 8 x 7 Garage Door in 10′ Wide Buildings) 36″ Single Door with Aluminum Floorguard Transom Windows above Garage Door Includes 2- 24 x 36″ Windows w/Screens Trim around Windows 2- Pair Shutters Rafters are constructed of 2 x 6s 24″ OC 3 ���Ridge Beam 10- Pitch Roof Hurricane Ties securing Rafters to Wall 7″ Gable Overhang Arch Gable Vents 4′ Loft on Gable of Building Roof consists of ��ng Tar Paper Standing seam metal roof. Insulated 100%. Climate control w/ mini split.


 
Sep 28, 2021     Ordered iPad, 12.9 inch primary display - (1 hour)       Category: Avionics
The iPad will be the "Tesla-Like" display. It will display:
Flight Instruments
Altimeter
Airspeed Indicator
Attitude Indicator
Slip / Skid Ball
Heading Indicator (HSI)
Ground Track
Course Pointer
Course Deviation Indicator
Outside Air Temperature
True Airspeed
Density Altitude
Ground Speed
GPS Altitude
Local and Zulu Time
Flight Duration
VFR Navigation
Moving Map
Nearest Airport Navigation
Direct-To Navigation
Flight Plan Navigation
Database of US Airports, Navigation Aids, Waypoints
NMEA output to popular autopilots
ETA / ETE estimator
Automated waypoint / destination briefing
Situational Awareness Features
Air Traffic (ADS-B)
Traffic Alert
NEXRAD Weather Radar (ADS-B)
Terrain Profile View
Terrain Alert / Warning
Airspace Map Display
Current / Upcoming Airspace
Runway Assistant
Runway Incursion Alert
Descent Rate Alert
Airspeed Decay Alert
Altitude Alert
Unusual Attitude Alert
VHF Communications
Nearest airport frequency
Flight-plan airport frequencies
Recent frequencies
One-touch for active airport


 
Sep 28, 2021     Placed Falken Avionics Order - (3 hours)       Category: Avionics
Includes:
FlightView EFIS Lite Hardware Kit: FlightBox Pro EXP + Air Data Computer $2,000
FlightDock iPad Mount $200.00
Trig ADS-B Out + Transponder Bundle $2,650
Belly-Mount Permanent Install ADS-B In Antenna Kit $100
Complete Trig COM Radio Bundle $1,400.00


 
Sep 28, 2021     Prototype Article - (2 hours) Category: Research
 


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