Oct 30, 2023     Fixed a faulty Carb Heat sensor reading - (2 hours) Category: Avionics

I had a bad splice that was resulting in no carb heat reading, redid the splice and checked it with the ohm meter this time

  Mar 22, 2023     ELT Gremlin fixed - (3 hours)       Category: Avionics

Could not work on the nose bowl today, the superfill did not dry overnight as it was too cold in the hanger, so….

I had to get the ELT working, it took:

Several trips crawling back into the tail playing with switches
2 trips to Walgreens
2 trips to ACE
2 phone calls

Who would have known the system needed two different odd sized batteries to make the system work. But the remote horn and panel remote are all working now.

  Mar 16, 2023     Radio PTT - (2 hours) Category: Avionics

PTT gremlin was found and eliminated, it was a ground issue in the pilot side from the stick to the Deutsch connector. �th stick PTT were perfectly with a positive confirmation as “loud and clear” from inside the hanger.

  Mar 07, 2023     Fired Up the Panel - (13 hours)       Category: Avionics

Two days of work to pull everything together, get the wiring all service looped and secured. This included remounting the ACM (red box), hooking up all the D-Subs. I had to untangle and reposition the harness wires many times to try to make it the most clean and efficient. Both avionics trays are now permanently secured. Wires are looped and secured via standoffs from a bar between the two fuselage bars that the avionics trays are adel clamped to.

  Feb 26, 2023     Clean up and protect aft wiring - (2.5 hours)       Category: Avionics

Aft wires got a hose sleeve and spiral wrap to protect them from abrasion. Installed a zip tie wrap holder on the firewall to secure wires.

Made a diode jumper for the starter solenoid

  Feb 25, 2023     Added Alternator Shunt and changed Fuse Location - (2.5 hours)       Category: Avionics

I had to splice in connectors for the shunt in the alternator wiring.

I also moved the alternator fuse closer to the power source to be more efficient

  Feb 23, 2023     Ignition Key Power - (.5 hour)       Category: Avionics

Attached the key switch power to the main power buss

  Feb 23, 2023     Alternate USB Plugs - (1 hour) Category: Avionics

Mounted and wired the behind the panel USB plug. Grounds are attached to the buss and the power is attached to the D-Sub

  Feb 23, 2023     Alternator / Voltage Regulator - (3 hours)       Category: Avionics

Mounted the regulator on the firewall and ran all the wires to their respective locations both to and from the regulator. Installed the 2amp inline fuse on the wire that attaches to the main power buss

  Feb 22, 2023     Wire Routing/Planning - (4 hours)       Category: Avionics

I decided it would be dangerous to start cutting wires and connecting/splicing wires before I had a solid plan for how the wires would be routed so as to have known wire lengths to deal with. So today I put fasteners on the firewall, mocked up standoffs for the engine mount and ran the wires through sleeves to make everything very clean.

I have attached a photo showing how my mentor used hose and high temp zit ties for routing wires

I will use this method to make standoffs from the engine mount, here are my temporary attach points to get create my wire routing.

Attached are photos of the routing and sleeves I am using to keep thing clean looking.

The above (last photo) will have the red/white/black wires spliced to the yellow/black/red wires and the sleeve will be slid to the left through the zip tie location. All zip ties will be high temp zip ties, the ones you see are GripTies that are easily removable.

I am trying to be as creative as possible to make things as clean looking as possible.

  Feb 16, 2023     Electrical Cables - (1.5 hours) Category: Avionics

Made the electrical cables for:
Alternator to 60amp fuse
60amp fuse to master
Starter solenoid to starter
Main battery negative to firewall passthrough stud

  Feb 06, 2023     Ground Bus - (2 hours) Category: Avionics

Installed the ground bus and a brass 5/16” brass bolt with the head cut off to run negative through the firewall. The brass bolt allows the engine and battery to be grounded

  Jan 13, 2023     Wiring Day, hooking up network harnesses and building D-Subs - (5 hours)       Category: Avionics

Installed Comm and GPS antennas. Installed D-Sub for the gps to connect to the network system

Control Stick PTT, spliced the two grounds into one for the D-Sub. After the spliced used shrink wrap and installed the D-Sub. All plugged into the ACM

Temporarily installed the pilot side headset jacks

Hooked up all the network harnesses creating a huge mess that will be cleaned up and secured with service loops.

  Jan 11, 2023     Terminated coaxial cable end - (1 hour) Category: Avionics

ADBS, Comms and Transponder coaxial cable ends were installed on the cables and attached to the appropriate avionics

  Dec 28, 2022     Finished AP Servo Harness - (3 hours)       Category: Avionics

Wired the D-Sub plugs at the servos, secured the wires and connected. Shrink tubing goes into the D-Sub plug and has another layer that terminates at the plug housing.

  Dec 27, 2022     Installed Connectors for the Control Sticks - (2.5 hours)       Category: Avionics

Laid out the PTT wire routing, installed a grip tie tie down to secure the wires/tubes to the deutsch connector. Installed the male deutsch connector to the pilot and co-pilot PTT wiring. Triple shrink wrapped the wires leading to the deutsch connector. Secured the roll servo harness wire to the tie down. Safety wired the connection to the roll servo

  Dec 26, 2022     PPT and AP Harness - (3.5 hours)       Category: Avionics

Cut hole in floorboard under right seat to all the routing of the PTT wires from the control stick to pass down and forward as well as the AP Servo wires to pass up to the servos. Installed the Servos in the brackets and secured with safety wire.

  Dec 24, 2022     Engine Monitors and CHT's - (5.0 hours)       Category: Avionics

Cut a hole in my left avionics tray to allow the EGT/CHT and Engine Thermo wires down for the firewall pass-through on the left side. Final mounted the Backup Battery and Engine monitor box on the tray as well as the ACM. ACM might need to come off as it is blocking access to one of the adel clamps needed to secure it to the tubing. AP harness wires are all laid out, just waiting to decide on the final/exact routing then cut to length and install the D-Sub. Installed the CHT probes

  Dec 23, 2022     More Wiring - (2.5 hours)       Category: Avionics

Working on control stick and AP servo wiring

  Dec 21, 2022     Wiring - (4 hours)       Category: Avionics

The control PTT wiring with disconnect modules and the wires from the disconnect to the COM harness which is spiral wrapped. The AP servos are now wired and the D-Sub attached to both servos.

  Dec 15, 2022     Wire routing - (2 hours)       Category: Avionics

Worked out the wiring layout from the forward station up to the right avionics tray. Ordered spiral wrap to secure the wires together. More to come

  Dec 13, 2022     Nutplates and trays - (5 hours)       Category: Avionics

Fitted boxes on the top and the ACM on the bottom. I used 1” nylon spacers on the bottom to give relief from bolt heads and the fuselage tubing for the ACM. Everything is still loose fit in regard to the bolts as there will be more on and off to cut holes in the tray for wires to pass through and install grommets

  Dec 11, 2022     Avionics Trays - (3 hours)       Category: Avionics

Final Cut the trays after installing the fresh air scat tubing so I see the clearance needed. Drilled holes for the nutplates, then primed and installed the nutplates

  Dec 07, 2022     Trimmed Avionics Tray - (1 hour)       Category: Avionics

Trimmed the avionics tray so there is very little overhang in the middle to eliminate the tray edge form possibly chaffing wires/harnesses

  Dec 06, 2022     Wire conduit and Running wires - (2.5 hours)       Category: Avionics

Cut the conduit and then ran the headset jacks so they can be mounted on the wing root panel. Ran the Comms coaxial cable through the conduit to the right avionics tray

Started attaching the wiring harnesses to check for proper lengths reach.

Checked several mounting locations for the ACM.

  Dec 06, 2022     Avionics Box Trays - (1.5 hours)       Category: Avionics

Used the template to mark up and then cut the trays for the remote avionics. One for each side.

  Nov 11, 2022     Installed the Panel - (2 hours)       Category: Avionics

Hung the panel for the initial fitting, it will need to be removed to drill holes for the throttle and mixture

  Apr 06, 2022     Wire retention and wires - (2 hours)       Category: Avionics

Installed the wire retention devices to hold the wires for the run up to the panel area. Also installed ADSB, Transponder and ELT wires and ran them to the panel area

  Apr 04, 2022     ADAHARS Tray - (3 hours)       Category: Avionics

Had to fabricate a tray for the ADAHARS so it is +/- 1.0 degree of level to the fuselage's level datum. I got it to 0.1 degree of level. The tray has three bends to attain the correct orientation.

  Mar 22, 2022     Antenna trays - (4 hours)       Category: Avionics

Completed and installed the Transponder and ADSB antenna trays/mounts

  Mar 09, 2022     GPS and Comm antenna shield - (6.5 hours)       Category: Avionics

Who would have thought it would take six and a half hours to make/fit/install two mounting plates. The stringers are not parallel so that added time. I used angle aluminum at the front and back of each shield to make them extremely stiff. I ran out of time, so the GPS plate/shield still needs to be riveted to the stringers.

  Feb 20, 2022     Static Port tubing - (.5 hour) Category: Avionics

I plumbed the static ports up to the firewall area. The “T” still needs to be secured to the brace, I am waiting on the proper bolt size to arrive

  Feb 16, 2022     Static Port location finalized - (.5 hour)       Category: Avionics

Upsized the holes for pull rivets and then riveted in the mounting plates

  Feb 12, 2022     Installed the Static Ports - (1.5 hours)       Category: Avionics

Fabricated the plates, put in a 90 degree bend to mount on the stringer. Cut a 1/2” hole via step up drill process for the static port. Used Clickbond glue to attach the port to the plate. Drilled, the plate and match drilled the stringer for permanent rivets.

  Dec 02, 2021     ELT Mount - (3 hours)       Category: Avionics

Fabricated and installed using adel clamps, I later added a bend to the front edge to add stability