Sep 29, 2023     Avionics - (7.9 hours)       Category: Avionics

Found markings on pitot static fittings in Stein kit and looked up specifications. Tried both the SMC KQ2 and MettleAir fittings. Decided I like the SMC best since it seemed to require the less force to use and still seemed to be secure. The release ring on the MettleAir fittings seemed to work better but I had trouble determining if the tube was seated.

Looked at the possible routing path for the static lines and the pitot and AoA lines.

Called Stein and discussion bending tubing, fitting torque and routing options with tech support.

Installed fittings in GSU and G5. Researched and ordered sealant with teflon for the alternate static switch. Tried several options and made up tubing assembly for the pitot line between the GSU and G5 (see picture). The bends in the tubing are left over from when it was packaged in a roll for shipment.

Tried several options and decided to use a SMC cross fitting for the static lines between the GSU, G5 and alternate static switch. Started research on where SMC parts could be purchased and what was in stock.

Tried heating and bending the tubing several different ways and found one that works well. Also researched other SMC tubing that works with the KQ2 one touch fittings and tried to find sources and colors. Need to call the distributor on Monday.

Tried to use the Stein tubing on the showplanes static port that was included in the Stein kit. Also researched the showplanes kit on vansairforce. I plan to stay with the Van's rivet solution unless I find problems later on.

  Sep 20, 2023     Avionics and Electrical and Registration - (2 hours) Category: Avionics

Met my work goal for another week. I'll be out of town from tomorrow through 9/26.

Looked at pitot fittings and tubing and researched on the web and VansAirforce. Tried forming the tubing using a heat gun. Started to call Stein since I am using their kit and ended up submitting a question using their contact form.

Noticed the Garmin sensor section on the Stein website and looked up my sensors to confirm I had the post SB sensors. Also researched orifices and added three to my McMaster Carr cart and made research notes.

Worked on aircraft registration documentation and organized and researched a list of questions. Completed web searches. Called Vans and asked about the empty $ field in the bill of sale. Called EAA and left a message. Called FAA too late in the day. Dug through all my parts invoices and made a spreadsheet of all the parts from Van's so I could fill in the $ field in the bill of sale if needed.

Spent over 6.8 hours on my project and counted them towards my weekly goal, but only logged 2 hours on the builders log.

  Sep 19, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics

Opened engine box to retrieve documentation for FAA registration. Found out both numbers I needed were on the outside of the box. It looks like I got the Avstar fuel injection instead of the AirFlow performance.

I canceled my Solidworks subscription since I am through with mechanical drawings, at least for now. It was very handy for the instrument panel design.

I flipped the instrument panel assembly so it is now right side up and I have access to the locations where I need to install pitot static AOA lines. I opened the parts kit from Stein and was surprised that the tubing and connectors didn't have any markings on them. I expected the parts to indicate compliance to a DOT spec for air brakes like my old safeair1 kit from Avery. I'm going to call Stein tomorrow with a few questions.

Downloaded the new revision AU of the G3X install manual and reviewed all of the changes. I think the only one that affects me is the new capability to calibrate AOA with no flaps and full flaps which is a nice feature. I already have the wiring for a flap position sensor so I don't have to change anything to use the new feature. The manual also included more examples on how to the advanced gauge configuration which should help me when I get to that point.

I spent another 4.7 hours in the garage moving things around so I could open the engine box and be ready to work on the fuselage.

  Sep 17, 2023     Avionics and Electrical - (3.3 hours)       Category: Avionics

Completed organizing and tying the bundle of wires on the copilot side. Now I have three groups of wires. One going to the engine compartment that are still in several bundles because I don't know how I will route them through the firewall. And two bundles that will go back to the airframe to components and sensors.

Take a look at the before and after pictures below.

Read the Paul Dye kit planes article about using a Piper blade pitot with the Garmin AOA system. I have a Piper blade pitot and made the mounting doubler. I'll have to rework it to use the Garmin Pitot that I purchased. I think I will use the Garmin Pitot, but reserve the right to change my mind if reworking the mount is too painful.

Logged in to Garmin to register my avionics and decided to wait since I don't have a registration number confirmed by the FAA.

Started working on registration documents after reviewing and deciding not to use the online CARES process due to privacy issues with the required Google Authenticator App. Need to call Van's with a question and open my engine box and get the documentation and engine serial number. Need to call the FAA about my N number reservation.

  Sep 16, 2023     Avionics and Electrical - (6.1 hours) Category: Avionics

Met my goal for the week, but wish I had done better. I decided to allow myself two extra days off this week. We got in bed Wednesday at 2:30AM after a late flight from Hawaii and I decided to allow myself to take Wednesday off to recover. I felt sick on Thursday and took that day off also. I met my goal on Friday and Saturday.

Now that the instrument panel wiring is complete enough to allow testing I am continuing to clean and wrap a few things up.

I cut and applied heat shrink to about six quick connects on the fuse block that were incomplete due to previously running out of heat shrink. I pushed all the quick connects into final position on the fuse blocks, switches and diode-or diode blocks.

I checked and created labels storage for the Mouser order for D-Sub covers. I'll use these when I disassemble everything for installation into the airframe.

Continued to make notes about the assembly, remaining tasks and started new parts order from Aircraft Spruce.

Organized and tied wires going from the pilot side of the bulkhead back to the airframe. I had created rolls of single wires or groups of wires as I had cut and installed wires to each component in the airframe. I unrolled, combined wires, and tied the combined wires back to where the first wires ended. The combined bundle of wires is about 0.56 inches in diameter and should fit through one piece of conduit. The new bundle is ready to be installed in conduit.

I started the same wire organization task on the copilot side of the bulkhead.

  Sep 15, 2023     Avionics and Electrical - (2.5 hours) Category: Avionics

Completed finding and labeling storage for all the remaining parts in the Aircraft Spruce order.

Reinstalled the bolt between the feed wire and the circuit breaker box using a metal locknut in the Aircraft Spruce order. Worked on notes for the assembly drawing while installing new screws for the fuse block, installing an Adele clamp on the ground wires and calculated screw lengths to use in other locations.

  Sep 14, 2023     Avionics and Electrical - (0.8 hour) Category: Avionics

Missed my hourly goal the week of 8/20 and 8/27. Used the time to deal with work on the house (roof, solar panel removal), take care of work and preparation for leaving 8/28 for a two week trip to visit my daughter and her family in Hawaii for 2 weeks.

Completed unpacking the Aircraft Spruce parts order, making sure I received everything and storing all the Adele clamps in a plastic storage box with labels.

  Aug 23, 2023     Avionics and Electrical - (6.3 hours) Category: Avionics

Received reply from Garmin on my issues. Worked some more and resolved all the issues.

Transponder fault - confirmed that it was most likely because I didn't enter the aircraft information yet. I may find a different problem when I do that, but for now it is working as expected.

Unable to select and configure some analog and digital inputs - there was a software bug that messed with some of the GAD 27 inputs so you could see ones you had configured, but not edit them. After I updated software that started working as I expected. The GEA 24 inputs seemed to have a similar problem even after the software update. Garmin explained how it really works so all is okay. There are two GEA 24 configuration tabs, GEA24 inputs and GEA24 discrete (digital) inputs. The GEA24 inputs tab shows all the analog inputs and 7 general purpose inputs. The GEA 24 discrete inputs tab also shows the 7 general purpose inputs. Before they are configured, they show up with a “-“ in the “type” column. You can see, select and configure them from either the inputs tab or the discrete tab. On the inputs tab, you can only configure them to be an analog type input. On the discrete tab, you can only configure them to be active high or active low. Once you configure them on one of the tabs, you can only edit them on the one tab (inputs or discrete). If you edit them and set the input type to “none” again you can select and edit them from either tab.

GAD 29 ARINC 429 not showing up on the main display, but LEDs flashing like the GAD 29 was communicating on the CAN bus and all was well. Garmin suggested sending it in for test/repair. I decided to do a little more testing and found out that if I left the power and CAN bus connector plugged in and disconnected the connector with the ARINC 429 bus signals the GAD 29 module showed up on the main display and had the latest software already installed. So I opened up the ARINC 429 bus signal connector and found I had put one of the pins in the wrong place. Why would that keep the system from working? Maybe because I had connected one ARINC 429 bus pin to a position that was marked as “reserved”. I had just put it in the wrong channel or swapped polarity I bet the GAD 29 would have shown up properly on the main display, but of course the ARINC 429 communications would have failed and I would have looked at the connector and found the problem easily.

Repaired the GAD 29 connector after completing the trouble shooting above. Replaced labels on the first blocks to match the way I had actually wired them. Updated the schematic to match the changes. Cleaned up wiring to the GAD 27 terminal block by reducing the length of some wires and rerouting. Cleaned up some other wire routing problems such as wires to the CO Detector and tied more wire bundles.

Reviewed shopping carts and notes to complete an Aircraft Spruce order.

The instrument panel wiring is basically complete and working although I need to move everything to the fuselage and connect up other components instead of just simulating them one at a time.

  Aug 20, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics

Tried a few things to troubleshoot the three issues. Sent an update to Garmin with details of the GNX375 errors which just seem to be configuration issues.

Explored more G3X functionality and tried screenshots, configuration backup, and direct to navigation on the G3X and GNX375.

Replaced more tie wraps with lacing and cleaned up some more. I attached three pictures looking from the bottom up between the instrument panel and the bulkhead.

  Aug 20, 2023     Avionics and Electrical - (7.2 hours)       Category: Avionics

Met my goal for another week!

Even better, today I finished all the initial testing of the wires to and devices on the instrument panel. I sent an email to Garmin G3Xperts asking for help on three things; GAD27/GEA24 configuration issues, GAD29 not recognized and a transponder fault message.

Updated software on the GNX 375 and installed the database. Updated software on the G5 and on the GDU460. The GDU handles updating all the other G3X system devices.

Continued testing and troubleshooting the issues after I sent the email and thought of more things to try.

Updated the spreadsheet and schematic to show the power to the P Mag circuit breakers coming from the main bus instead of from a fuse.

Updated the wire list spreadsheet with information on all the connections I tested.

  Aug 18, 2023     Avionics and Electrical - (8.7 hours)       Category: Avionics

Continued testing fuse block, breaker and wire connections. Note: Skipped GTR discrete 1 and 2, pilot and copilot PTT and headset and mic jacks since they were previously tested. Connections tested were:
GAP status.
Seat Heat power for pilot and copilot.
Start active.
Pmag power and enable right and left.
Ignition switched and ground.
Master switch and ground.
Starter ignition switch and ground.
Trim power circuit breaker, GAD 27 pitch and roll trim motor power and trim switches from pilot and copilot. I temporarily connected a trim motor for the test. I thought I would be able to use the G3X "trim" menu in the configuration mode to move the motor, but found out I had to use the pilot/copilot controls. I assume the "trim" menu will work after I complete configuration and connections for the GSA autopilot. I also spliced one of the trim power motor wires that was damaged (probably before I received the wire).
Switch and power to the aft power port.
Strobe, NAV/POS and Taxi right and left switches
Landing light connections including switch to GAD 27, Light power to the GAD 27, and GAD 27 power to the landing light wires.
Flap motor power to the GAD 27, flap switch connections to the GAD 27 and GAD 27 power to the flap motor. I noticed that the GAD 27 applied a 8 to 10 volt signal to the flap motor wires even if the flap power circuit breaker was open if the wires were not connected to a load. I confirmed that a load of a small trim motor would not move unless the flap power circuit breaker was closed.
Fuel pump power and switch.
Pitot heat power and switch.
GNX to ELT RS-232 signal using a scope. Also spent time reviewing and testing other RS-232 signals between the GNX, G5, GDU and GSU. I don't think I was able to confirm all of them.
Alternator Field Breaker.
Alternator current sensor and battery current sensor wires to the GEA by connecting a Hall effect sensor. The power wires to the panel were looped through the Hall effect sensor twice and I could verify operation by turning the G5, GNX and GTR and verify the current changed.

I continued troubleshooting two issues and am ready to send an email to Garmin support.:
GAD 29 CAN bus connectivity: I am unable to see the GAD 29 on the device list on the GDU. There is an "A429" in the list, but the box does not have a green check or a red x and the LRU information is not displayed. The GDU shows 0% network errors. The GAD 29 status led is blinking green which is supposed to indicate "On and communicating using the CAN Bus". I did notice that the green status LED on the GAD 29 starts flashing immediately when power is applied. The green status LED on the GEA, GAD 27 and GSU turn green when power is applied, but don't start flashing until about 20 seconds after power is applied to the GDU 460. I disassembled the J291 connector and verified the pinout was correct for the CAN-H and L signals. I made a temporary J291 connector that only had power. When I connect it to the GAD 29 the status LED illuminates to a solid green and does not start flashing.

When I go to the GDU configuration mode "Engine & Airframe" page I see 4 tabs: GEA 24 inputs, GEA 24 discrete, GAD 27 inputs, and Settings. I have been able to go to the input and discrete tabs and configure and calibration inputs and in many cases see the status of the input so I can test the wiring. Sometimes I see an input that I was previously able to configure and see blue text which means I can select it and change it. Other times I see an input that was I was previously able to configure (I can see the name I assigned) that is displayed in white. When that happens, I am unable to select it by touching it or using the knobs. I saw this when the Garmin LRUs were running the original software (purchased Fall 2022 and all received by Jan 2023). I updated the G3X LRU's with the latest software and now I only see this issue on the "GEA24 Discrete". I've only rebooted a few times so I don't know if the issue with the other tabs is really resolved or not.

I updated software on the G5 and the GNX375 after I updated software on the G3X LRUs.

I am also going to ask Garmin about a "GNX 375 needs service." "Transponder has failed." error message.

  Aug 17, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics

Started testing wiring. Started with xxx PWR 2 (IBBS battery backup power). Tested all the grounds individually one at a time. Verified power to the GEA, GNX, GTR, GAD27, GAD29, GSU, GDU, GMC and GMU.

Then started testing power 1 connections by installing fuses in the avionics fuse block one at a time and verifying function of the same list of devices. Then started adding fuses to the main fuse block and checking power and ground to additional devices such as the G5, GSB (USB) charging port, landing light power to the GAD 27, IBBS battery backup and CO detector. Installed temporary "master" switch between main battery and main fuse block since I won't wire in the master contractor until I install the panel in the airframe. Verified proper operation and switching between using main power and backup power.

Verified power connections through Autopilot circuit breaker to GSA pitch and GSA roll. Updated schematic to show circuit breaker names that match the labels on the panel.

Started testing all the connections to the avionics by temporarily connecting sensors (pressure, temperature) or resistors (temperature, position) or frequency generator to airframe wires to simulate connections to final sensors. Tested CHT/EGT, oil temp, oil pressure, fuel pressure, manifold pressure, RPM left and right, fuel flow, fuel level left and right, position of pitch, roll and flaps, Trim power, pilot and copilot trim inputs (up, down, left, right). Also confirmed operation of flap up/down switch, OAT sensor. Did not repeat testing of headset and microphone connections for pilot and copilot.

  Aug 16, 2023     Avionics and Electrical - (3.2 hours)       Category: Avionics

Finished connecting wires to avionics fuse block. Started connecting wires to the main fuse block.

  Aug 14, 2023     Avionics and Electrical - (5 hours)       Category: Avionics

Continued wire routing cleanup by changing power and ground wiring to combine wires that were previously in separate bundles. Changed routing of some GAD 27 and power and ground wires. Installed another Adele clamp to support power wires going to the fuse block and grounds. Decided to change positions of some of the fuses on the avionics fuse block due to the length of some of the wires to the fuse block. Completed about 1/2 of the wire connections to the aviation fuse block.

  Aug 13, 2023     Avionics and Electrical - (3.5 hours) Category: Avionics

Continued work on cleaning up wiring. Updated spreadsheet with connections that were tested. Worked on routing of wires to engine bridge, regulator and fuse and ground blocks. Rerouted wires to GAD 27 TB273. Ready to drill a hole for a new clamp and make all the fuse block connections.

  Aug 12, 2023     Avionics and Electrical - (3.1 hours) Category: Avionics

Met my weekly hour goal for another week. Attended the Chapter 187 monthly meeting and talked to friends about progress and plans. Didn't get any of my questions answered (meeting time not included in hours today).

Tested more connections and found the way to test the flap up and down inputs. Still not sure how to test the other flap related signals and the A429 and GAD 29 connections. Decided I should wire power to all devices and then upgrade all the Garmin products before spending more time trying to test. Investigated and ordered SanDisk 32GB SDHC and microSDHC cards.

Looked at remaining wires to route and complete and investigated multiple options.

  Aug 11, 2023     Avionics and Electrical - (5 hours)       Category: Avionics

Updated schematic with DC light wiring changes. Removed GNX PWR 2 connections except for the ones to the Diode-OR circuit.

Completed the IBBS/Backup Battery connector wiring and tested IBBS connections to the G3X.

Completed the connector for the IBBS/Battery current sensor and configured and tested it on the G3X.

  Aug 10, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics

Completed panel lighting test, figured out a feature of the GAD 27 lighting controller. Decided to add the output for DC lighting control 2 and 3 and use for the GTR and GMC inputs. Made wiring changes and tested. Made final DC lighting control connections with a service loop for future changes if needed.

Continued to clean up wiring.

  Aug 09, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics

Updated spreadsheet with connections that were tested on 8/8. Finished cutting remaining wires to switches and circuit breakers to final length and terminating them. Cleaned up routing and spliced all the panel grounds together. Cleaned up routing and spliced all the power 2 leads together (backup power bus). Temporarily connected battery power to fuse panel and circuit breakers. Temporarily connected battery to ground block forest of tabs. Temporarily connected battery to IBBS (backup battery) connector.

Powered up most of the Garmin devices and started testing the DC lighting bus. GTR, GSB, GNX, GDU and the GAD 27 control are working great. The GMC control works differently and needs more testing.

  Aug 08, 2023     Avionics and Electrical - (5.8 hours)       Category: Avionics

Completed enough connections to the instrument panel to start power on testing. Verified separate power 1, power 2 and ground connections to the GMC, GDU, GSU, GEA, GAD 27, GAD 29, GNX, and GTR before powering up combinations of those components. Also checked power 1 and ground connections to the G5, CO detector and GSA 28 roll and pitch servos.

I needed to test power 2 connections separately before connecting all the power 2 connections together into one backup power bus. I needed to test all the ground connections separately because each device can also connect each other device to ground through the shield and chassis grounds. I wanted to verify I hadn't missed any individual connections.

Then I started powering up combinations of instruments and configured and verified the following connections using clip leads and switches or knobs:
GAD 27 discrete inputs.
GAD 27 dimmer inputs and outputs.
GEA discrete inputs.
GTR discrete inputs.
I started checking GEA general purpose inputs and configurations.

I learned a lot about G3X setup and configuration. It makes a lot of sense to me although I am still not able to find where to set and test the flap control inputs and outputs.

I found Revision AT of the G3X installation manual had been released. I downloaded and reviewed changes. Most were related to the new GHA 15 Height Advisor which I do not need.

  Aug 07, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Started using lacing tape to tie small bundles of instrument panel wires together. Decided this would be easier and cleaner than trying to group, maintain and then tie large bundles.

  Aug 06, 2023     Avionics and Electrical - (1.7 hours)       Category: Avionics

Started work on wiring cleanup and completion on items on the instrument panel. I'm working from left to right. Secured a few wire bundles using silicone fusion tape and tie wraps to attach bundles to click bond mounting points. Used silicone fusion tape where bundles might rub.

  Aug 05, 2023     Avionics and Electrical - (8.3 hours)       Category: Avionics

Met my weekly goal for another week even though I had quite a bit of TK work to do.

Verified the new field voltage test jack worked with the plugs and fabricated a test plug and the cable for the test jack.

Completed the dimmer light cable by using two splices to convert a single ground and power connection to three grounds and power connections and installing three connectors.

Completed assembly of the engine bridge connector.

Installed more pins in the IBBS battery backup cable.

Started review of cable routing and moved some wires around to improve appearance and reduce the size of the wire bundle underneath the bulkhead and from the left side of the bulkhead to the back of the airplane.

Looked at GNX manual and calculations show I can't use the current location of the transponder antenna. Did some quick searches and realize I need to move the antenna to a location near the rudder pedals or just in front of the spar. I might be able to install the COM antenna near where the transponder had been located. The doubler I installed there isn't really big enough for the COM antenna footprint, but I could replace the doubler or let the COM antenna extend past it.

  Aug 04, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics

Completed temporary connectors for GMU and both GSA autopilot servos. Started working through spreadsheet to cut wires needed for wiring in the instrument panel area and for bench testing.

  Aug 03, 2023     Avionics and Electrical - (2 hours) Category: Avionics

Reviewed and placed Mouser order for terminals and a d-sub connector cover. Measured remaining Giga-flight CAN bus cable and estimated the remaining amount needed. I may have to order more. Started terminating wires for the GSA pitch and roll servo and the GMU..

  Aug 02, 2023     Avionics and Electrical - (2 hours) Category: Avionics

Worked on IBBS connector and wires.

  Aug 01, 2023     Avionics and Electrical - (9 hours) Category: Avionics

Continued cutting, routing, labeling and terminating wires to switches and other parts on the instrument panel and bulkheads. Made progress and ran into some problems such as not having the right d-sub connector for the engine bridge PMAG monitor and the field voltage test point jack and receptacle don't work together; the plug isn't long enough. Found a new connector to order. Searched for a new plug and jack combination.

  Jul 31, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Continuing to cut wires, terminate them when practical and labeling wires for switches and circuit breakers from left to right on the panel. Removed brass bus strip from both circuit breaker sets and trimmed ends. Added #10 hole for power wire to the main circuit breaker bus.

  Jul 30, 2023     Avionics and Electrical - (3 hours)       Category: Avionics

Cut, terminated and labeled wires for the master and ignition switches. Removed installation brackets from Click Bond tie wrap pads.

  Jul 29, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics

Just met my weekly goal for the short week. We were visiting parents in San Antonio for three days.

Cut and routed wires for grounds on switches installed on the panel. Soldered wires to the timer, log event and toga switches. Soldered wires to the other side of each switch. Crimped quick connect terminals on the flap and back up enable switches.

Created a new panel ground symbol and updated 6 switches to use the panel ground instead of the avionics ground. Decided I needed to install Click Bond tie wrap pads before starting more wiring on the panel. Read up on click bond installation instructions, cleaned, scuffed and cleaned the panel locations. Mixed up CB200 adhesive and installed 8 CB9302V3 Click Bond pads. The before and after pictures below show the click bond pads with the installation fixtures still in place.

  Jul 25, 2023     Avionics and Electrical - (6 hours)       Category: Avionics

Cut CAN bus cable to length for GEA. Terminated it and the CAN bus cable going to the Roll Servo which is the next CAN bus device in the chain. Finished assembly and organizing wires for the GEA J241, J243 and J244 connectors.

  Jul 24, 2023     Avionics and Electrical - (3.8 hours)       Category: Avionics

Completed the CAN bus wire splice for the GAD 27. Assembled the J271 connector. Created markups to use when assembling the GEA connectors.

Decided to clean up the cable bundles more and separated and grouped the yellow DC lighting bus, Red Power 2 wires, Red Power 1 wires, and the black avionics ground wires. Started cleaning up routing for loose wires on the GAD J271 connector and for some of the wires coming from the back of the instrument panel.

  Jul 23, 2023     Avionics and Electricalcs - (1.9 hours) Category: Avionics

Received heat shrink tubing for printer and printed remaining labels on list. Printed a few additional labels. Added labels to any GEA 24 wires that were missing them. Cut additional lengths of black heat shrink tubing so they are ready when I terminate shielded wires.

Looked at list of additional parts I need and reviewed carts at Aircraft Spruce, Sten Air, Mouser, Digikey and McMaster Carr. Added more parts to the list. Decided I can continue making progress with what I have and wait to order them.

  Jul 22, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Missed my weekly goal and sent my daughter $50. I missed a few days and planned to make them up, but unexpected work came up Friday and Saturday and I ran out of heat shrink labels.

Installed shield terminations and crimped pins on all wires for the GEA engine monitor J241, J243 and J244 connectors except for the CAN bus connection and the GEA to GDU cable. Waiting on heat shrink tubing labels to arrive before installing pins in the connector body.

  Jul 22, 2023     Avionics and Electrical - (4.7 hours)       Category: Avionics

Completed assembly of the GDU cable with the shorter CAN bus. Printed labels for more wires and ordered more heat shrink tubing for the printer. Measured and cut all the wires for three of the connectors on the GEA 24 engine monitor. The remaining connector only has wires for the EGT and CHT sensors and will be easy to complete later.

  Jul 20, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Continued work on rerouting wires. Completed almost all the cleanup of existing wires. Decided on length of CAN bus cable to GDU and cut the cable and terminated the shorter cable.

  Jul 19, 2023     Avionics and Electrical - (2.1 hours)       Category: Avionics

Drilled holes and temporarily installed adele clamps. Masked avionics areas with towels and tape to keep chips out and vacuumed work area after drilling. Continued working on wire routing.

  Jul 17, 2023     Avionics and Electrical - (4 hours)       Category: Avionics

Cut and terminated the final wires for GAD J271 and installed the pins in the connector body except for the CAN bus.

Reviewed wire connections for each of the GEA 24 connections to help plan wire routing.

Removed CAN bus pins from GDU connector to allow rerouting the cable and reducing the length so it fits in the bundle better. Explored several options for bundling existing wires and decided where to install the next adele clamps.

  Jul 16, 2023     Avionics and Electrical - (5 hours)       Category: Avionics

Worked on the dimmer harness today. Tried to use the 2x2 pin molex Micro-Fit 3.0 connectors that I had modified and realized while they barely fit through the instrument panel hole in one direction they didn't work so well in the other direction and wouldn't fit through the washer and nut. Decided to use the 3 pin one row connector and only install the connector housing after the dimmer potentiometer is installed in the panel.

Added connector connection and part number detail to the schematic now that I decided what parts to use. Cut wires for the pigtails on the potentiometers.

Struggled with crimping the pins and sockets and inserting pins and sockets into the housings. Finally figured it out after using some practice parts.

Soldered wires on the three potentiometers and crimped pins on the wires. Installed the three potentiometers in the panel and inserted pins into the housings.

  Jul 15, 2023     Avionics and Electrical - (8 hours)       Category: Avionics

Met my hourly goal for the week and made some good progress today.

Started work on GAD 27 connectors. Completed cutting wires, making terminations and assembling connectors J272 and TB273. Completed all labels, wire cuts and terminations on J271 except CAN bus and Dimmer inputs. Renamed some wire names for the LED light and updated the schematic and spreadsheet.

  Jul 14, 2023     Avionics and Electrical - (6.7 hours)       Category: Avionics

Started cutting wires and temporarily placed labels for the GAD 27 connections and some instrument panel switches and circuit breakers. Printed additional labels as needed. Many of these connections end with long wires that will go to components far away from the instrument panel. Terminated some of the wires such as the one to the fuel pump switch and added the current limiting resistor used to sense fuel pump active.

Updated schematic and spreadsheet to change the text from "FUEL P ON" to "FUEL P ACTIVE" to be consistent with starter active text.

  Jul 13, 2023     Avionics and Electrical - (3.4 hours)       Category: Avionics

Started looking routing of existing wires. Pulled all power, ground and lighting bus wires loose from the shielded cables to clean up routing. Added an Adele Clamp at one end of the bundle. Decided to finish cutting wires to the GAD 27, GEA 24 and the rest of the airframe before finalizing wire bundle routing and clamp positions.

  Jul 12, 2023     Avionics and Electrical - (1.3 hours)       Category: Avionics

Completed assembly of the GMC 507 connector and tested cable fit for GMC installed and GMC pulled out far enough to disconnect it.

  Jul 11, 2023     Avionics and Electrical - (2 hours)       Category: Avionics

Disconnected the battery and antenna cables. Turned the panel and bulkhead assembly 180 degrees so I would have good access to the bulkhead panel.

Completed termination of CAN bus. Drilled 1" hole for GMC cable in bulkhead using step drill. To get the connector to fit through the hole the grommet and shell of the connector must be removed. Now I understand why they offer a tray for the GMC 507 and wish I had opted for that solution.

  Jul 10, 2023     Avionics and Electrical - (6.2 hours)       Category: Avionics

Applied power to all the components and started configuration setup and checking connections and operations.

The GTR COM radio receives and transmits using either pilot or copilot headset. Right and left audio is correct. PTTs and discrete input 1 and 2 both work. The connections are all made to the GTR. I used test leads to connect the headsets, PTTs and discrete inputs. The audio connection to the GDU is working.

The GNX acquired enough satellites to determine position. Set up serial ports and ARINC ports and tried to test. Haven't finished testing.

GDU is still working. Continued setup for new components added. The GAD 29 doesn't seem to be recognized by the GDU even though the status LED on the GAD 29 indicates the CAN bus is connected with no errors. Maybe the GAD 29 connections are okay, but the GNX is not trying to connect over ARINC due to incomplete setup. The CAN bus between the GDU and GTR is working and I can see GTR frequency settings and transmit status on the GDU. I'm still trying to figure out how to use the configuration pages for all the Garmin components.

Printed labels and cut remaining wires for GMC 507. Terminated all wires except for the CAN bus.

  Jul 09, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Completed terminating the CAN bus for the the GTR. Assembled GTR connector and backplane.

Made temporary ground planes for the COM, GPS and Transponder antenna. Applied power to the GTR and GNX and both powered up okay.

  Jul 08, 2023     Avionics and Electrical - (3.7 hours)       Category: Avionics

Met weekly goal for hours on the project again. Back on track! Cut remaining wires for the GTR connector and terminated them all except for the CAN bus cable. Determined route and length of CAN bus cable between GTR and GMC and GMC and GAD 27 and cut two pieces.

Not included in the hours, but I also attended the EAA chapter meeting this morning and asked questions about the starter solenoid and showed pictures of progress on the panel to a few people.

  Jul 07, 2023     Avionics and Electrical - (2 hours)       Category: Avionics

Double checked that there were pins in all the expected connector holes for the GNX. The pins looked good, but I discovered I had installed one connector upside down and corrected the problem. Decided not to power up the GNX without antennas before confirming nothing would be damaged by doing that. Ordered some low cost cables from Amazon to use for testing if needed.

Reviewed all the connections to the GTR200 and GMC507 and decided how to route the cables. Estimated GTR wire lengths again now that I know more about wire routing.

  Jul 06, 2023     Avionics and Electrical - (6 hours)       Category: Avionics

Inserted terminated wires into the connector body for the GNX connector J3751. Inserted two of the pins in the wrong hole and had to extract and move them. Had a lot of problem with the extraction tool on this Positronics connector even though the extractor tool worked great on the other connector made by TE. Looked up tools and connector specs to verify I was using the correct tool. Finally I was able to extract and move the pins.

Completed power splice and some additional wires for J3752. Completed connector assembly and built and installed the backplane. [had to correct orientation of one of the connectors the next day - did you notice the problem from the picture 2532?]

  Jul 05, 2023     Avionics and Electrical - (8.2 hours)       Category: Avionics

Terminated all wires for GNX connector J3751 after cutting a few missing wires to length. Made power and ground splices for J3751. Need to pin J3751 and then cut power and ground wires for J3752 and terminate them and pin J3752.

Updated the schematic and wire list to simplify wiring of these two connectors.

  Jul 04, 2023     avionics and Electrical - (2.1 hours) Category: Avionics

Connected power to 5 components (G5, GDU, GSU, CO Detector and GAD 29) one at a time and then all together. Temporarily connected the OAT sensor to the GSU 25. The short CAN Bus is working even though one end is not terminated. Looked at diagnostics and configuration screens on the GDU and G5. Configured the serial ports. Tested the CO Detector to GDU serial connection and confirmed an error is displayed when the CO Detector is in test mode. Changed baro setting on GDU and confirmed the setting was updated automatically on the G5. Saw the OAT matched room temperature and was displayed on GDU and G5.

  Jul 03, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics

Completed connections for CO detector including switch and LED.

Worked on wire routing for the GNX and GTR. Taped Diode-Or components in place. Covered unused pins.

Printed wire labels for GNX and GTR. Cut and terminated wires for GNX and GTR for power to the Diode-Or.

Looked up assembly instructions for GNX high density connectors with separate shield blocks. Labeled storage bin for high density pins.

  Jul 02, 2023     Avionics and Electrical - (4.8 hours)       Category: Avionics

Finished up GAD 29 connector. Terminated shield wires and attached to shells. Worked on CO detector connections.

  Jul 01, 2023     Avionics and Electrical - (2 hours) Category: Avionics

Missed my goal for the week and sent my daughter $50. I was planning on taking two or three days off due to oral surgery on Monday morning, but didn't get back to work until Saturday.

Completed terminating the GAD 29 wires, but didn't assemble the connectors.

Spent a few hours on Tuesday and Wednesday putting recent Aircraft Spruce and McMaster Carr parts in organizers and labeling them. Also drove out to the hangar to pick up some clamps and organizers.

  Jun 25, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics

Realized I needed a better way to begin securing the harness during the assembly process. Cut short lengths of paint stir sticks, drilled holes for tie wraps, and clamped the pieces to the bulkhead.

Completed connections and connector assembly for GSU except for shield terminations to shell. Started working on GAD 29 connections and completed all except CAN related ones.

  Jun 24, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Met my hourly goal for another week. I'm making progress although it seems slow to me. I need to step up the number of hours a week above my goal.

Still have a box full of Garmin install kits (connector bodies, housings, pins).

Completed the connector for the G5 J51. Started working on connectors for the GSU and finished one except for ground shields and the second one except for the CAN bus splice. I like the way the cables will route to the G5 and GSU although I did leave one CAN bus cable between the GDU and G5 a bit on the long side.

  Jun 23, 2023     Avionics and Electrical and Engine - (6.6 hours)       Category: Avionics

Received the engine. The box seemed to be in great shape. I'll wait a while to open it...

Cut additional wires to length. Focusing on the G5, CO detector, GSU and GAD 29. Started terminating the connector for J51. It has the lightning protection module (LPM) and also has the CAN bus splice so it is different than all the others. Researched and also completed several practice splices. I'll verify I completed all the crimps tomorrow morning and then start heat shrinking splices and shield terminations and then assemble the connector.

  Jun 22, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics

Assembled and completed connectors GDU P4601 and P4602 except for connecting the ground shields to the connector shell. Documented the CAN bus termination splice on the schematic and in the wire list. Connected Power 1 and then Power 2 to a battery to see the GDU 460 power up for the very first time and verify both power connections.

Explored and decided on an option for the cable service loop for the GDU. Decided on a similar loop that is ~19 inches long for the G5 and will wire it next.

Printed all the heat shrink tubing labels for the G5, GSU, GAD 29 and the CO detector.

I didn't log the hours, but spent another 3 hours in the garage organizing things so I can get rid of some file cabinets and have room for an engine crate.

  Jun 21, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics

Ordered pitot/static/AOA parts from Stein Air. Ordered mechanical and electrical hardware from McMaster and Aircraft Spruce.

Worked on GDU connections. Prepared and terminated wires and shields so they are ready for connector assembly. Prepared CAN bus with a splice for CAN termination in the GDU connector. Prepared PDF1 ID jumper.

Received call from FedEx Freight and scheduled Lycoming engine delivery for Friday, 6/23/2023.

  Jun 20, 2023     Avionics and Electrical - (5.2 hours)       Category: Avionics

Decided to place the backup power splices below the GAD 27 near the DC Lighting splices.

Figured out an approach to print and manage heat shrink labels and printed labels for the GDU connectors and for the labels on the other end of each of the GDU wires.

Finished cutting the remaining wires for the GDU connectors and started terminating them. Will shrink the labels when I assemble the connectors and figure out the best location for them. Read through the termination and connector housing assembly instructions again and found more parts I needed to order. I added the parts to my McMaster Carr and Aircraft Spruce shopping carts. I also added more ring terminals to my Mouser cart.

Continued looking at parts and options for completing the Pitot/Static/AOA plumbing and decided to use a kit from Stein Air.

  Jun 18, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics

Completed all of the new "labels" column on the spreadsheet by changing GNX and GNX DOR information information. Made a few more GNX related schematic changes. Decided not to change fuse naming on the schematic and wire list. Decided on fuse positions and created labels for the fuse blocks using more pilot friendly names. Added the naming and position information to the schematic.

  Jun 17, 2023     Avionics and Electrical - (6.2 hours) Category: Avionics

Met my hourly goal for another week. Went through the wiring spreadsheet and finished almost all of the new "labels" column by using the wire name column and adding wire color and pin number information. Modified some wire names and added lines for additional labels when needed. Modified schematic when needed. Added notes to the schematic. Decided on different wire splicing for GNX and completed changes on the schematic. Need to finish GNX changes on the spreadsheet.

  Jun 16, 2023     Avionics and Electrical - (8 hours)       Category: Avionics

Finalized mounting location of Diode-Or blocks for the GNX, GTR and ELT. Decided on general location for the backup power splices. Updated schematic symbol to show connections to "AC" in and "+" terminals.

Updated schematic and wire list to show CAN bus order and changed CAN bus terminations. Assigned wire colors to all connections that used shielded cable. Added a column for wire labels and started entering data that includes pin numbers and, on shielded cable, wire colors.

  Jun 15, 2023     Avionics and Electrical - (2.5 hours)       Category: Avionics

Decided on the location for the Diode-Or packages. Decided on a general location for the splice for the backup power connections between the TCW IBBS and Garmin Power 2 inputs. See picture.

Updated schematic and wire list spreadsheet with CAN Bus device order wire names for all the CAN Bus cables. Added the CAN Bus terminator for the GMU 11 and added a connection to the GDU for CAN bus termination.

  Jun 14, 2023     Avionics and Electrical - (6.9 hours)       Category: Avionics

Printed and cut out paper labels to use for initial wiring while waiting for new heat shrink print cartridges. Grouped wire supply by size and labeled each group. Confirmed colors of wires in shielded cables.

Started cutting shielded wires for some of the cables going between two components installed in the panel. Then started working through questions that came up during connections to the GDU 460. Decided to run a single ground to the GDU. Decided on the order of components on the CAN bus.

Decided on device order for CAN bus routing. Starting from the end behind the instrument panel to the end in the fuselage:
GDU 470 (CAN termination), G5, GSU 25, GAD 29, GTR 200, GNX 375, GMC 507, GAD 27, GEA 24, GSA 28 Roll, GSA 28 Pitch, GMU 11 (CAN termination)

Started working on where to install the backup power bus and whether to use a terminal block or a yellow AMP PIDG butt splice. Decided to use a splice after testing how it worked to place thirteen 20 AWG wires in a single splice (7 on one side and 6 on the other). See picture with the protective plastic cut away for better visibility. I got this idea from an Aeroelectric example. Also worked on a mounting location for the Diode-Or packages and added a screw for mounting them to the McMaster Car order.

The plan is to route all the wires to the GDU and terminate the GDU connector. Then test to have enough service loop to allow the GDU to be unscrewed and disconnected without the service loop being too long and interfering with other components behind the panel. Then I will repeat this process on the G5.

Checked on engine status. It should ship any day now.

Sent email to Superior Components (Instrument panel company) asking about their new thin EL panel.

  Jun 13, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics

Determined I needed to use Click Bond parts to secure wiring to the instrument panel. Found my parts and determined I already had what I needed. Found a good source (The Flight Shop) for adhesive and cleaner and placed an order.

Modified Molex minifit 3 four pin connector by sanding enough of the housing off so it will fit through the dimmer switch holes in the panel. It is now a three pin connector which is all I needed.

Reviewed wire name list and prepared a file to use in printing the labels for the wires. Figured out how to print again using the label editor software and excel and started printing. Ran out of heat shrink tubing quickly. Estimated the amount of heat shrink I would need and placed an order. Also researched and placed an order for label tape with high adhesion and for vinyl self lamination overwrap labels for cables with BNC connectors already installed. Determined I need to update the wire name list to add pin numbers for the individual wires.

  Jun 13, 2023     Avionics and Electrical - (2.6 hours)       Category: Avionics

Mocked up different examples of wire routing and discussed ideas with Ellicia. Thought through the process and decided I need to route most of the wires before terminating any and leave enough extra at each end of the wire so I can change routing before terminating wires if needed. Decided I need to label every non-shielded wire with the wire name and the pin number. Decided I need to label every shielded cable at each end (but not the individual wires in the shielded cable) with the wire name. I'll use printed heat shrink for labels and temporarily secure them with blue tape. I'll heat shrink the labels as I trim and terminate the wires. I may add pin number labels to all the individual wires in a shielded cable as I am terminating them.

Reviewed wiring section 11 of AC43.13-1B which covers wire routing, labels, bend radius, supports, service loops and other good information to help me use best practices.

  Jun 10, 2023     Avionics and Electrical - (5.6 hours)       Category: Avionics

Met my hourly goal for another week.

Continued adding nut plates or drilling final mounting holes for the CO Detector and ELT Alert that use #4 mounting screws. Reassembled bulkhead and ribs to instrument panel so it is ready for wiring. Considered different options for wire routing.

Reviewed and added parts to McMaster and Aircraft Spruce shopping carts. Ordered replacement hose for pneumatic tools from Cleaveland.

Started looking at pitot/static/AOA plumbing options again. Looked more closely at my choice for a starter contactor and wiring after learning more about contactors at the chapter meeting.

  Jun 09, 2023     Avionics and Electrical - (10 hours) Category: Avionics

Started marking, drilling #6 holes, drilling nutplate mounting holes and countersinking them, drilling initial hole to final size, deburring, priming and installing nut plates for the avionics. Almost done and will post pictures with the update tomorrow.

  Jun 08, 2023     Avionics and Electrical       Category: Avionics

Verified previous McMaster and Aircraft Spruce shipments matched order. Started marking details of where avionics will be located and taking pictures. Considered trade-offs of moving some of the components. Created a mockup of two different center stack radio braces. Removed the bulkheads and ribs from the panel so I can start drilling holes and installing nut plates for avionics.

Scaled a document from enginebridge.com to make a template.

Added an extra jack to the Mouser list. Will use this as storage for the plug needed for the Alternator Field voltage test point.

  Jun 07, 2023     Avionics and Electrical - (3.4 hours) Category: Avionics

Worked on list of parts to order next. Researched material that should be used for foam to cushion the fuel lines, selected polyethylene based on FAA lists of material for use in aircraft cabins and chemical compatibility with fuel. Worked through the list of screws needed for avionics that I previously missed. Decided to delay order for McMaster Carr and Aircraft Spruce until I make more progress and figure out other things I have missed.

  Jun 06, 2023     Avionics and Electrical - (.5 hour) Category: Avionics

Researched shield terminations for floating shields in Garmin documentation. Increased insurance limit to cover the new engine that should ship in the next week.

  Jun 05, 2023     Avionics and Electrical - (5.9 hours)       Category: Avionics

Determined mounting location for other avionics that will be located in the structure between the instrument panel and the firewall. Decided to install the IBBS battery backup on the rudder bar center support instead of the bulkhead. Decided to use nut plates for mounting installation and selected parts and placed orders for nut plates and other hardware. Forgot to order all the mounting screws.

  Jun 04, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics

Continued installing the rest of the components in the instrument panel. Fabricated two bus bars for the circuit breakers using a fence on my drill press. The "completed" panel looks really good. Now all I have to do is figure out where to put the rest of the parts behind the panel and complete all the electrical wiring and pitot/static/AOA plumbing.

  Jun 03, 2023     Avionics and Electrical - (8.8 hours) Category: Avionics

Met my goal for time spent on the project for another week.

Test fit panel with racks into RV. Increased the width of the cut out in the center bulkhead by 0.3" with a nibbler and hand shears and confirmed fit. Removed instrument panel, structure behind it and the top skin. Cleaned up the center opening in the bulkhead.

Assembled the instrument panel, bulkhead and ribs on my workbench. Made and installed wooden spacers between the instrument panel and bulkhead. Started installing components on the instrument panel to help identify best places for components on the bulkhead. Fabricated a nut plate for the ELT remote control and spacer washers for the BNC connectors.

  Jun 02, 2023     Avionics and Electrical - (8.8 hours)       Category: Avionics

Continued the process of fitting the installation racks and replacing the nuts with nut plates. Added an 0.032 spacer between one of the angle brackets and the rack to center the rack better (compensates for uneven placement of the aluminum angle on the panel. All done except for replacing the 8 screws with new ones that are the right length and haven't been partially damaged by many installs and removals.

Filed on edges of instrument panel and screw holes to improve the fit and allow all the screws to be installed.

Test fit instrument panel with rack installed and then did a rough trim on the bulkhead center hole for clearance for the instrument rack on the left side (approximately 0.3").

Sat in the airplane with the instrument panel installed and thought about the assembly order. I want to leave the top skin off as long as possible, but it gets harder to install the longer I wait.

  Jun 01, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics

Worked on fit and installation of the rack. Enlarged holes in angle aluminum on panel to allow the rack to be located properly. After holes were enlarged used nuts and a washer to install and check fit of the rack and the components in the racks. Started the process of replacing the nuts with nut plates one at a time. Test fit a lot of times.

  May 30, 2023     Avionics and Electrical - (3 hours)       Category: Avionics

Studied the fit of GNX375 and GTR200B installation racks and marked and drilled holes. Test fit parts and started work to improve the position.

Received notice from Van's that my engine would ship in 7 to 10 days so I started the process to make the final payment.

  May 29, 2023     Avionics and Electrical - (7.2 hours)       Category: Avionics

Completed install of top fuselage skin and test fit panel again. Checked for alignment and size of cutout in bulkhead and think I need to enlarge it.

Filed on instrument panel to correct fit problems previously found including:
Corners and one side of each rectangular switch hole.
Keyway and inside of ignition switch hole.
All sides of the dimmer potentiometer holes.
Access panel to get it to fit better.
All sides of the power port hole.
Bottom outside edges of panel to lower the panel and provide more clearance to the side rails and top of panel to fuselage skin.

  May 27, 2023     Avionics and Electrical - (8 hours)       Category: Avionics

Met my weekly goal for a 6 day week.

Continued test fitting of components on new panel.

Things that fit: BNC bulkhead connectors, grommet for BNC cable, TOGA switch, Alternate Static Port switch, Circuit Breakers, GSB15, CO detector button and LED, ELT control panel, MyGoFlight mount, GMC507, install racks for GNX375 and GTR200.

Things that didn't fit: Power Port (too small), Access Panel (too tight even after removal of portion of panel affected by overdriving a rivet. Also noticed all the access panel screws had been longer and cut to rough length), Ignition Switch (too small), 10K Vishay potentiometer (dimmer controls - too small), Otto K1 switches (height and width okay, but corner radius not small enough). Noticed that round holes for circuit breakers and ignition switches didn't seem to be cut cleanly with a small bump where the cut might have started and ended.

Reviewed documentation and figured out how to install the racks for the GNX375 and GTR200 to the front panel and roughly marked hole location.

Started McMaster Cart for screws needed for: ELT control panel, MyGoFlight mount, install racks, access panel, ground bus, and instrument panel mounting screws.

Cut out center stack clearance hole in center bulkhead and added the 7 degree bend. Reinstalled the bulkheads and structure behind the panel to verify the new 7 degree bends didn't cause any fit problems and that the bulkhead surface was now flat. The clearance hole in the bulkhead may need to be enlarged on one side. Installed the top skin and test fit the panel again. It fits although it is tight against the top skin. Need to remove some tape, cleco more of the top skin and decide if I need to reduce the outside dimensions of the panel. I test fit the GMC507, G5, and GDU460 avionics in the panel.

  May 26, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics

Picked up finished panel. Inspected and test fit panel. I didn't try the fuselage skin and the mounting holes to the skin, but so far it fits and overall it looks good. I'm finding some problems.

I fixed loose PEM nuts around the access panel using an arbor press. The access panel door has an interference fit and needs work. Some rivets attaching the backing plate for the access panel were over driven and distorted the backing plate.

Aluminum angle parts for radio trays were installed on wrong sides and do not align vertically with cut out in panel. The gap between the angles and the sides of the cut out are not equal. The parts were not deburred before they were riveted.

The line graphics on the copilot side had some breaks. The line width of the source material was the same on the pilot and copilot side and the pilot side printed okay.

The 90 degree bend at the bottom of the panel wasn't 90 degrees all the way across the panel.

Removed panel and bulkhead structure from the fuselage. Marked and bent the 7 degree angle in the two side bulkhead panels. Measured actual location of radios in finished panel and used SolidWorks to determine the cut out in the center bulkhead panel. Center bulkhead is marked and ready for cutting.

  May 25, 2023     Avionics and Electrical - (3.7 hours) Category: Avionics

Found out panel was ready for pick up. Paid for panel and arranged to pick it up on Friday morning.

Received Mouser parts and compared switches with switches from Stein and decided to use Mouser parts. Tried new connectors on Amploc sensors and decided to use the original connectors on the 100A sensors and the new connectors on the 25A sensor. Stored parts.

Used solidworks to created images showing cut out for center stack radio. Marked rough cut out on panel and tried to decide on where to install avionics and run wiring.

  May 24, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics

Printed a full scale instrument panel at Fedex for final review. Completed background, sizing and export to PNG of the graphics for the switches on the stick grip. Completed instrument panel markups with powder coat colors, graphics for the switches on the stick grip and some questions. Completed one more round of minor changes and then approved the final version.

Researched type of fittings to use for pitot/static/AOA lines.

  May 23, 2023     Avionics and Electrical - (.5 hour) Category: Avionics

Received powder coat samples for instrument panel and made a decision to use "Viking Grey". Opened, inspected and put away splices received from Powell.

Checked for latest prices on solder sleeves and placed an order with online components.

  May 22, 2023     Avionics and Electrical - (4.8 hours) Category: Avionics

Compared APEM and Stein TOGA switches and decided to use the Garmin recommended Apem. Tried the Stein PTT switch and decided to order some C&K switches that might work better. Tried the S03-03 solder sleeves and decided to order a pack of 100 that will be more than enough to finish the wiring. Tried the connector that Amploc recommends and don't like it for the 25 Amp sensor. Searched, found and ordered two other types from Mouser. Ordered some additional Otto gaskets now that the instrument panel thickness is finalized.

Decided not to run a long cable for a music jack to allow it to be installed near the headset jacks. Will use a 24 inch cable and hide the jack behind the instrument panel for future use if needed.

Updated the schematic by removing the CAN auxiliary connector, updating the bus current table and updating the reference designators. "Released" the revision 5 document and started a revision 6 where I will document as built changes such as wire color and CAN device order.

Archived a revision 5 wiring spreadsheet that matches the revision 5 schematic and started a revision 6 spreadsheet.

  May 21, 2023     Avionics and Electrical - (1.1 hours) Category: Avionics

Was out of town almost all day. Opened and inventoried shipments from Digikey and Stein.

  May 19, 2023     Avionics and Electrical - (2.8 hours) Category: Avionics

Met my goal for another week. Will be out of town Saturday so it was only a 6 day week.

Worked on new graphic for stick grip switches. Used two layers so I can change the background color easily.

  May 18, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics

Completed CAD work on ignition switch angles. Completed markup of panel and sent email to panel supplier.

Reviewed panel supplier responses. Considered options and ordered powder coat samples.

  May 17, 2023     Avionics and Electrical - (6 hours) Category: Avionics

Resized second draft of panel and printed full scale drawing at FedEx Kinkos. Completed careful review of panel design and decided on changes and addition of two switches. Started work on sketches showing ignition switch graphics to allow good comparison between two options provided by designer and the metal plate provided by ACS. Found discrepancies.

Organized parts to be ready for wiring the panel assembly.

  May 16, 2023     Avionics and Electrical - (6.5 hours) Category: Avionics

Continued work finding best source for parts.

Explored options for solder sleeves instead of the Garmin suggested sleeve with braid.

Researched and selected crimp on ferrules for use with connections to the P-mags and CO detector.

Ordered all the wire I calculated I will need so I won't need to order any more. Until I run out of something... Ordered from Stein Air, Aircraft Spruce and Wiremasters.

I had been planning on installing one or two defog/avionics bay exhaust fans. After talking to Van's support I decided I can do without a fan and add it later if needed.

Ordered more splices and a few of the Garmin recommended solder sleeves and some other random parts I'd been saving to combine into one order. Once I try the Garmin recommended solder sleeves I will make a final decision on what to buy and place one more order.

  May 15, 2023     Avionics and Electrical - (7.8 hours) Category: Avionics

Created a pivot table on the spreadsheet and merged my wire inventory data with the wire needed. Noticed where some of the pivot table data didn't make sense so went through several iterations of corrections. Noticed I hadn't been consistent with wire color for power and switched power. Made final decisions on wire colors and updated the spreadsheet. Noticed and corrected some wire name inconsistencies. Decided on three sources for wire depending on availability and price. Started reviewing the existing cart for Stein Air and Aircraft Spruce and deleted or saved items not needed and added lines for all the wire.

Reviewed wire order list a final time and made decisions of how much extra to buy of each wire type.

Looked at splice and solder sleeve counts on the spreadsheet and determined I need to buy at least 30 blue splices and 6 sleeves for shield cable with 1 conductor, 33 sleeves for 2 conductor and 33 sleeves for 3 conductor. Started looking for sources.

  May 14, 2023     Avionics and Electrical. - (4.5 hours) Category: Avionics

Added two new switches and wires to the spreadsheet and schematic. Reviewed spreadsheet and made final decisions on some wire sizes and updated the spreadsheet as needed. Made other corrections to the schematic. The spreadsheet is ready to use for purchasing wire.

  May 13, 2023     Avionics and Electrical. - (6.4 hours) Category: Avionics

Met my time goal for the first week of this phase.

Completed review of changes in the G3X install manual revision AS. Discussed some of the changes with Brian at the EAA monthly meeting. Discussed how to route wiring and Pitot and AOA tubes from the panel area to aft of the main wing spar.

Continued work on spreadsheet by creating a pivot table to find the number and types of wires routed through the spar and other bottlenecks and by creating a pivot table to identify the total length of wire needed for each color and type of wire. Reviewed and cleaned up data as needed when the pivot tables didn't make sense.

Entered information from previous wire inventory in spreadsheet so I don't order wire I already have.

  May 12, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics

Continued adding wire length and path information to the spreadsheet and checking wire sizes. Finally completed full pass through spreadsheet. Completed checking spreadsheet to verify I didn't miss any entries. Saved a version of the spreadsheet. Then removed old tables and started updating some of the tables to show the new wire length, size and path information.

Started reviewing the G3X install manual revision AS changes to see if there were any impacts to my design. There are several new configuration options for discrete inputs that I may use or add such as "user timer start stop" and "log event marker".

  May 11, 2023     Avionics and Electrical - (3.4 hours) Category: Avionics

Printed a larger version of the Superior ignition mounting hole and label and measured angles. Drafted a new version of the ignition mounting hole and sent to Superior.

Continued work adding wire lengths to the spreadsheet and checking wire sizes.

  May 10, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics

Completed review of panel and notes and markups. Sent notes and markups to Superior.

Continued work adding wire lengths to the spreadsheet and checking wire sizes. Decided to change the GMC 507 power wiring to get power 1 and power 2 from sources like the other avionics instead of from the same breaker as the autopilot servos. This allowed reduced wire size and length for the GMC 507. Updated spreadsheet and schematic.

  May 09, 2023     Avionics and Electrical - (6.5 hours) Category: Avionics

Reviewed and, if needed, researched each item on draft panel layout from Superior and provided mounting hole details and hole dimensions. Marked up changes to add or modify text. Marked up changes to move some items. Drafted an email with additional questions and notes.

  May 08, 2023     Avionics and Electrical - (6.1 hours)       Category: Avionics

Completed order of CAN bus cable. Continued work on spreadsheet by adding more wire lengths and routing and changing some wire sizes after seeing total lengths.

Discussed some panel questions with Superior ATX. Researched COM antenna questions. Reviewed first draft of panel layout. I like it better than the starting draft I submitted to them. Printed a full scale version and compared it to my full scale version using a "light table", AKA window, to verify the first draft component location doesn't interfere with structure behind the panel. Studied the first draft to decide what changes I want.

  May 07, 2023     Avionics and Electrical - (2.4 hours) Category: Avionics

Starting phase 4. Continuing with the goal of 4.5 hours per day average when at home without guests from out of town.

Continued adding lengths and paths to spreadsheet.

  May 06, 2023     Avionics and Electrical - (1.7 hours) Category: Avionics

Continued work on spreadsheet adding lengths and path information. Decided to order 65 feet of CAN bus cable and route it from the tail to the wing and then to the panel instead of having the panel in the middle.

  May 05, 2023     Avionics and Electrical - (1.2 hours)       Category: Avionics

Completed update of panel notes and sent to Superior ATX along with pictures of the latest mockup. Also asked about project start date and found they didn't have a record of receiving my prepayment so paid with a credit card.

Filled out the two forms Van's Aircraft requires for generating a Bill of Sale and submitted them to Van's. I need to Bill of Sale to submit documents for registering my RV.

  May 04, 2023     Avionics and Electrical - (1 hour) Category: Avionics

Sat in fuselage and tested the reach of the MyGoFlight iPad mount to see if the mounting position I picked would work for me and Ellicia.

Printed panel layout notes and compared against the panel mockup to verify I hadn't missed anything on the panel or the list. Made notes about missing parts and changes of names.

  May 03, 2023     Avionics and Electrical - (1 hour)       Category: Avionics

Completed cut out and placement of labels on panel mockup. Sat in fuselage and tested the new locations.

  May 02, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics

Worked on panel changes. Made new labels and modified existing labels to show "final" design. Started cutting out labels and test fitting on the panel mockup.

Also cleaned up and organized the garage the last few days.

  Apr 30, 2023     Avionics and Electrical - (2.4 hours) Category: Avionics

Starting phase 4. Need to decide on commitment.

Continued work on spreadsheet updates and wire length estimates. Made some schematic updates. Ordered a bus bar that I might use to connect the TCW battery backup to the "Power 2" connections of the avionics.

  Apr 29, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics

Met my goal for another week. I was out of town 3 days.

Continued work on spreadsheet by starting to add wire length estimates a finishing wire grouping.

Worked on updated panel layout by making new labels with labels on top of switches, new sizes for grommet feedthrough and grouping switches.

  Apr 28, 2023     Avionics and Electrical - (1 hour) Category: Avionics

Added column to spreadsheet to help organize wiring to make counting numbers of shielded cables in a bundle easier and help calculate length of wire to order.

  Apr 24, 2023     Avionics and Electrical - (3.8 hours) Category: Avionics

Reviewed the solder sleeve data sheets and measurements for different shielded cables and CAN bus. Determined I need to use S03-02-R-9035 for single conductor shielded cable. Determined I need to use S03-03-R-9035 for 2, 3 and 4 conductor shielded cable and Gigaflight CAN bus cable.

Searched for good sources of solder sleeves and splices.

Started updating spreadsheet with splice count and solder sleeve count. Also updated spreadsheet to be able to see the different sizes of solder sleeves. Made other minor updates to spreadsheet when I noticed missing or inconsistent data.

Searched Garmin documentation and videos and confirmed I should use blue wires for the CAN-L signal per the G5 install manual and one of the Garmin Aviation videos. Of course it doesn't matter as long and the wiring is consistent, but I wanted to match Garmin Documentation if possible.

  Apr 23, 2023     Avionics and Electrical - (6.8 hours) Category: Avionics

Spent more time practicing using splices and solder sleeves and trying several configurations. Decided to use the blue splices on CAN bus with three 24AWG wires on the bus side and one 20AWG wire on the connector side. This should work great except for the GMC 507 high density connector where I will have to use a 22AWG wire which is too small for the blue splice. So I will add an additional small wire on the connector side of the GMC 507 splice. I wanted to use the red splices with two 24AWG CAN bus wires on one side and a single 22AWG wire on the other, but it was difficult and unreliable to get two 24AWG CAN bus cable wires into the red splice. I've also tried using the blue splices with two 24AWG wires on the bus side and one 22AWG wire on the connector side and it seems to work, but doesn't meet the blue splice specification for wire size.

Worked on the CAN bus wire label and decided to use 16pt Arial and text of " CAN " on the 1/4" HS. When shrunk, this label is just over the 0.75" length specified in the Garmin manual to cover the end of the shield.

Determined I was missing 4 connectors on the GEA 24 install kit. Inventoried the remaining install kits and sent and email to Aircraft Spruce to see if they will send the missing parts or if I have to order them. I wish I had inventoried the kits last fall.

  Apr 22, 2023     Avionics and Electrical - (9.4 hours)       Category: Avionics

Met my goal for another week. Was out of town for three days.

I cleaned up my work bench and moved the light/magnifer to a better location before starting work today.

I actually made physical progress on wiring today. Completed a total of 8 crimps for the two configuration modules. The wires are tiny 28 AWG. I read up on what to use to strip the wires and almost bought a new strip tool. I ended up using the 26 AWG slot on my Ideal stripping tool that has the sharp edge blades for non tefzel insulation. Worked great. Luckily the Garmin documentation provided settings for the DMC crimper for this unusual wire size.

I practiced using the extraction tools on test crimps that I had inserted into D-Sub housings yesterday. I made some more CAN bus practice terminations and this time used a splice instead of crimping both wires into one D-Sub pin.

I tried using lacing cord for the first time and it seems easy. I'm glad I was planning on using lacing cord.

I made up sample labels for 22, 20, 18 and 14 gauge unshielded wires and for 1 conductor, 2 conductor, 3 conductor and 6 conductor shielded wire and RG-400 Coax and GigaFlight CAN bus cable.

  Apr 21, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics

Ordered mygoflight iPad mount so I can figure out the best place to mount it.

Opened and inspected the remaining parts from B&C.

Weighed wire we measured earlier this week. I will use this information to understand the weight penalty for using shielded cables instead of individual wires.

Looked up specs for temperature and heat gun nozzles to use on solder sleeves. Looked up specs on standard density d-sub contacts. Looked up specs to decide which wire stripper to use. Tested use of solder sleeves on both gigaflight CAN bus cable and twisted shielded pairs. Terminated 20, 22, and a pair of 24 AWG wires into M39029/63-368 and M39029/63-369 standard density contacts.

Installed test contacts into male and female D-Sub connectors.

  Apr 20, 2023     Avionics and Electrical - (1.9 hours) Category: Avionics

Looked at wiring documentation and organized questions for meeting with John.

Reviewed panel and discussed wire routing with John. Discussed alternatives, maintenance and failure modes.

Tried different panel layouts and researched options for wiring changes. Mocked up a iPad to show how it fit into a panel.

  Apr 19, 2023     Avionics and Electrical - (1.6 hours) Category: Avionics

Unpacked and inventoried parts received from B&C, Mouser, McMaster Carr and AMPLoc. Called B&C to report a shortage. Boxed and shipped some parts on a previous order to B&C.
Cut grommets from McMaster to see which size would work for a panel feedthrough for an antenna cable with BNC connector.
Measured wire lengths so I will know if I need to order additional wire.

  Apr 15, 2023     Avionics and Electrical - (.6 hour) Category: Avionics

Looked and schematic, panel layout, feedback from John and Z13 schematic and decided to keep a single TCW IBBS and the current backup power plan.

  Apr 13, 2023     Avionics and Electrical - (.2 hour) Category: Avionics

Read more feedback from John and responded.

  Apr 11, 2023     Avionics and Electrical - (.4 hour)       Category: Avionics

Sent notes and final data package to Superior Aircraft Components for the panel design.

  Apr 10, 2023     Avionics and Electrical - (.2 hour) Category: Avionics

Set up bill pay and scheduled payment for deposit for panel design and fabrication.

  Apr 09, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics

Created new labels for COM and NAV and GTR200 antenna and tried several different changes to the panel layout.

Reviewed parts in cart, added parts to press in pem studs and stand-offs and placed McMaster Carr order.

Placed order for additional hall effect sensor for backup battery current.

Reviewed parts in cart, added more and placed B&C specialty order.

Reviewed parts in cart and placed Mouser order.

Reviewed parts in Aircraft Spruce and Stein cart and decided to delay orders.

  Apr 08, 2023     Avionics and Electrical - (3 hours) Category: Avionics

Met my goal of hours for the week in spite of finding out about and watching live streaming of four games our grandson's baseball tournament on Friday and Saturday.

Reviewed feedback from John on my panel and electrical design. Decided on several changes and explained some previous changes I had made. Drafted emergency procedures for alternator out situation.

  Apr 07, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics

Updated list of parts on the panel for the panel designer with all the changes made since February. Added links to details and sketches for the ignition switch and 12VDC power port.

Discussed returning parts no longer needed to B&C and filled out RMA form.

  Apr 06, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics

Researched PEM standoffs for fuse block and avionics mounting. Reminded Superior Aircraft Components I was needing a quote.

Continued work on placing Avionics on the bulkhead between the instrument panel and firewall. Used solidworks and manual positioning of a few components. Found that my paper mockup had several issues and moved swapped a few parts to correct. Found that a missing 7 degree bend on the bulkhead causes the bulkhead to curve so the avionics aren't flat against the bulkhead surface. Progress, and a few more things to do. See pictures for the latest placement.

  Apr 05, 2023     Avionics and Electrical - (7.5 hours)       Category: Avionics

Completed review and changes on schematic and spreadsheet. The only remaining updates are CAN bus device order and estimating wire lengths.

Picked rough locations for the Garmin items located behind the panel. I want to use SolidWorks to help me pick final locations.

Updated panel layout with the latest switches and circuit breakers.

  Apr 04, 2023     Avionics and Electrical - (5.1 hours) Category: Avionics

Removed the second backup battery and associated connections. Moved the remaining battery backup connections to "Volts 2" since I only have two power busses. Researched and then added a 60A hall effect current sensor for the backup battery power. Updated the schematic and spreadsheet to show the 10 position avionics fuse block and the 16 position main fuse block and moved all the connections to the appropriate block. Added an avionics master switch. Still need to make all the connections to the fuse blocks and avionics master switch.

  Apr 03, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics

Discussed operation of the TCW backup battery with TCW. Confirmed that the "normal" operation will run the main battery down to ~11V which might be 10 or 20% capacity remaining and then switch to the TCW backup. Also the main battery will try to charge the backup battery until the main battery reaches ~ 11V.

If I want to run lights, fuel pump, flaps, etc on the main battery and run the avionics on the backup battery as soon as the alternator fails, then I will need to have an "avionics" master to disconnect avionics from the main bus and to remove power from the TCW sense/charge line. This allows me to decide when I will use each power source and whether the avionics will run from the main or backup battery.

I updated the wiring spreadsheet with several different options and decided I wanted to leave the trim and autopilot power connected to the main bus and the remaining avionics connected to the TCW backup battery. A single Otto K1 switch will work as the avionics master. I also confirmed a single TCW backup battery would be enough for my needs.

I created more panel switch labels. I created a 1:1 scale footprint for the ground tabs and TCW battery backup. Tried a few different switch layouts on the panel and started looking at where to mount all the avionics boxes.

  Apr 02, 2023     Avionics and Electrical - (4.2 hours) Category: Avionics

Today is our wedding anniversary. 35 years!

Continued analysis of power distribution and loads and battery capacity. I have a list of questions to ask TCW tomorrow. I'm considering adding a "Avionics Master" switch and changing the TCW IBBS 1 charge/sense line from a fuse to a pull-able breaker. I think I need to be able to power the avionics from only the main bus OR only the TCW IBBS backup battery. The design currently powers the avionics from the main bus with the TCW as backup. I think the current design will deplete much of the main battery before the TCW backup starts powering the avionics. I could switch off the main bus, but don't want to do that because I need lighting and possibly pitot heat and other things. If I leave on the main bus on and powering avionics until it is time to land there might not be enough power left to run the boost pump and landing lights.

  Apr 01, 2023     Avionics and Electrical - (6.4 hours) Category: Avionics

Met goal for another week. Was not able to spend any extra time.

Continued comparison and updates to schematic and wire list. Finished up all connections except CAN and details on power distribution. Reviewed counts of fuses, grounds, switches and other panel items to confirm I am not missing anything on the panel design. Archived copy of the schematic and wire list.

Started detailed work on power distribution and loads and capacity in case of alternator failure in hopes of being able to eliminate the second TCW IBBS backup battery.

  Mar 31, 2023     Avionics and Electrical - (1 hour) Category: Avionics

Returned from trip to San Antonio. Continued work on spreadsheet and schematic. Checked and updated GAD27, GAD29 and Tosten CS-6 and CS-8 connections as needed.

  Mar 29, 2023     Avionics and Electrical - (9.6 hours) Category: Avionics

Continued work comparing schematic and spreadsheet and making updates to delete some parts, fix discrepancies, improve wire names and add missing information such as wire routing and colors.

  Mar 28, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics

Continued work comparing schematic and spreadsheet and making updates to delete some parts, fix discrepancies, improve wire names and add missing information such as wire routing and colors.

  Mar 26, 2023     Avionics and Electrical - (2.3 hours) Category: Avionics

Printed latest schematics at FedEx. Started comparing spreadsheet and schematic and making updates to both as needed. Added baggage USB switch to panel layout and sent final layout to Superior ATX for a quote.

  Mar 25, 2023     Avionics and Electrical - (3.5 hours) Category: Avionics

Met goal for another week. Logged 35.3 hours which exceeds the 31.5 hour goal.

Continued work on spreadsheet and schematic cleanup. Reviewed and removed some duplicate columns. Made final decisions on antenna jacks and made graphics for panel layout. Inspected new 12VDC power port and made panel graphic for it. Tested the power port with the USB charger.

  Mar 24, 2023     Avionics and Electrical - (3 hours) Category: Avionics

(Not counted in the hours today: watched several EAA videos about registering an amateur build airplane, process for getting an airworthiness certificate and wiring. One wiring video said not to crimp more than one wire in a terminal.)

Researched question about terminating more than one wire in a terminal and found a document created by Bob at AeroElectric Connection showing an example of multiple wires in a ring terminal and a splice. Found a Garmin G3X wiring video that showed using three wires in a splice connector.

Made a table of AWG wire sizes and copper cross sectional area to help me understand what combinations of wire I can crimp in different terminals and pins.

Continued considering options for putting a bulkhead BNC connector on the panel from the COM antenna. This would allow connecting either the GTR200 COM radio or a handheld if I needed to connect it to the external antenna in an emergency. Found BNC bulkhead fittings to use for the COM and NAV antennas. Made inkscape labels for the panel mockup and tried a few locations.

Looked up temperatures to use for installing heat shrink tubing.

  Mar 23, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics

Continued work on panel layout. Created new images for circuit breakers with space for a bus bar. Created images for fuse blocks of various sizes. Created images for headset jacks and LEMO connector. Created new, smaller, horizontal label for stick grip switches. Talked to Tosten about laser marking and found it wouldn't work on the grips I purchased. Traded emails with ACS products about the size of their ignition switch.

Explored locations for headset jacks and decided to leave them off the panel and put them on the armrest behind where your elbow will rest.

Researched options for mounting fuse blocks and didn't find a good one. Looked at standoffs and studs and click bond options.

Researched other options for USB power and ordered a MyGoFlight Dual digital USB charger and a power port for it to see if they will fit.

Ordered the ACS ignition switch since I'm not getting good information from ACS Products.

Looked at video for Anti Splat easy exit bar and held the one I borrowed from a friend in place in my RV. It does't seem like it will work well so I don't plan to install it.

Tried running the fan on the battery and I am happy with the airflow and noise. I don't like the Stein grill so plan to order a wire one from Mouser to replace it.

Continued cleanup of spreadsheet and schematic.

  Mar 22, 2023     Avionics and Electrical - (5.4 hours)       Category: Avionics

Created images with labels for new circuit breakers and groupings of switches. Created images for the new ignition switch and throttle/mixture bracket. Created new label for the stick switches. Placed new images on the panel to create a new layout. Sent pictures and notes about the changes to see if I get more feedback.

Sent request for updated quote to the panel designer and fabricator.

Started looking at electrical loads to see if I want keep 1 or 2 of the TCW 6AH battery backups.

  Mar 21, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics

Started making wire list and schematic changes per discussions over the last few days. Removed start enable and starter button on the stick. Changed stick button to GTR200B Disc 2 which will be defined as Com Monitor. Removed wingtip COM antenna. Added powered LEMO connectors. Changed Trim Power, Flaps power, Autopilot Power, P-mag power left and right from fuse and switch to pull-able breaker. Changed from discrete switches for starter, emag enable and emag enable to a standard ACS ignition switch.

  Mar 20, 2023     Avionics and Electrical - (7 hours) Category: Avionics

Prepared questions and panel layout parts for meeting with John H and Luis. Reviewed E-Mag test instructions to decide on E-Mag switch organization.

Met with John and discussed options for simplifying the layout and electrical design and removing components. Discussed wire routing.

Met with Luis and sat in his RV to look at panel visibility under the glare shield, stick and knee clearance under a standard height panel, and locations for headset jacks.

Archived the revision 4 schematic and wire list to capture the current state before I remove parts. Started revision 5 documents to be ready for changes. Reviewed meeting notes and started researching changes.

  Mar 19, 2023     Avionics and Electrical - (4 hours) Category: Avionics

Unpacked the new Epson LW-PX700 heat shrink sleeve printer. Installed and learned how to use the software. Printed sample sleeves and tested different text sizes on 22AWG wire.

Unpacked TCW IBBS system and charger and connected cables to charge the IBBS. Unpacked the PC680 battery and Optimate charger and connected the charger to charge the battery. I'll use the IBBS and PC680 charger when I start the avionics wiring and testing.

Continued work on wiring spreadsheet.

Arranged to meet with a friend to discuss his panel feedback. Traded texts with another friend about panel feedback and arranged to see his RV on Monday.

  Mar 18, 2023     Avionics and Electrical - (8 hours)       Category: Avionics

Took latest panel layout to the Saturday AM EAA chapter meeting and discussed the layout with Deene. Considered his feedback and moved existing labels around. Decided on new images and groupings of switches and labels and created in inkscape. Taped new images on panel layout and sent to two friends for review/feedback. The attached images are the latest version.

Created draft email with starting requirements for panel design/fabrication.

Continued work on spreadsheet. Renamed a lot of the wires for consistency and better grouping. Continuing to add wires and routing notes. Looked up connector types for GPS, Transponder and COM radios. Looked up TNC and BNC connectors and assembly instructions to verify I had the correct crimp tool.

  Mar 17, 2023     Avionics and Electrical - (7.8 hours) Category: Avionics

Created a new panel layout with the G5 to the left of the G3X display. Added the fuse/access panel on the right. Moved the center stack radios up and changed the order with the GMC507 Autopilot is at the top. Printed 3 copies of the layout. Printed and placed existing switch grouping and label designs until I had one that seemed reasonable.

Continued work on wiring spreadsheet.

  Mar 16, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics

Continued work on wiring spreadsheet. Adding wire type and color. Adding path and count data. Updating wire names as needed to group wires differently and have names make more sense.

  Mar 14, 2023     Avionics and Electrical - (2.1 hours) Category: Avionics

Reviewed Aircraft Spruce quote, researched the optimate battery charger they quoted and ordered the PC680 battery, a TCW battery backup and charger and a stainless steel heat box. Ordered the optimate battery charger from Amazon.

Received an update saying my Lycoming engine build would start soon. I replied back asking if I would get AFP or Avstar fuel injection.

Printed three full size copies of the latest panel layout which has the G5 on the left and the center stack 0.5" to the right of center. Placed paper samples of switches, labels and other components on one print out.

  Mar 13, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics

Completed final research on heat shrink printers and placed an order.

Continued work on spreadsheet to add power and ground connections and wire names. Tried several different methods of looking at the data with pivot tables. Think I have what I need. One pivot table will show types of wire and total lengths. The other pivot table will show the number of different connections between key LRUs and the LRUs that connect to them. This might help me decide where to place the different Garmin LRUs.

Discussed mounting location with Deene and reviewed the instructions he told me to look at in the G3X installation manual.

  Mar 12, 2023     Avionics and Electrical - (4.6 hours)       Category: Avionics

Tried up update a Solidworks panel assembly and ran across technical difficulties. Created a new assembly consisting of the panel structure, G5, GDU460, GMC507, GNX375, GTR200B and fuse panel and prepared a document for printing and test fitting.

  Mar 11, 2023     Avionics and Electrical - (1.4 hours)       Category: Avionics

Met my goal for another week. Worked 31.8 hours which is just a bit more than the required 31.5 hours. Missed one day of working on it which is the only day I have missed since January 8 except for the week in California.

Created one new panel layout with G5 to the left of the GDU. Discussed panel layouts with Deene after the EAA Chapter 187 meeting. He recommended using my latest layout and had comments and suggestions about some of the switches.

  Mar 10, 2023     Avionics and Electrical - (9.4 hours) Category: Avionics

Continued working on new columns on spreadsheet. Found and cleaned up problems and missing information in schematic and spreadsheet. Completed first pass except for power and ground connections.

Sent request for quote and for servo installation questions to Aircraft Spruce.

Looked up metal bus bar material at K&S and McMaster Carr.

  Mar 09, 2023     Avionics and Electrical - (5.1 hours) Category: Avionics

Continued work on wire list spreadsheet. Gave up on current scheme to use pivot tables on existing rows to estimate wire to buy. It was too complicated and confusing. There were a lot of duplicates such as ones for multi-conductor cables and for entries from "A" to "B" and "B" to "A"

Added three columns (Wire type, length and path) and sorted spreadsheet by wire name. With all the wires grouped by name, I started filling in wire type and path (to/from info). With wire names grouped I was able to see multiple entries for each wire name and add wire type and path for each single conductor wire and for each bundle of wires (multi-conductor cable such as shielded twisted pair). All the duplicate entries got marked as "Copy" so they can be filtered out.

I realized I need to wait to estimate length and start wiring anything to the engine until I hang the engine and can determine best wire routing. I'm going to continue working on wiring between Avionics boxes and the rest of the airframe.

  Mar 08, 2023     Avionics and Electrical - (7.3 hours) Category: Avionics

Spent some time looking at alternate panel layouts. Reviewed feedback from friend and printed two more copies of the panel so I can cut one up and move avionics around. Looked for smaller switches.

Found and studied information on firewall insulation and feedthroughs on VAF forums.

Sent firewall penetration types, location and grouping questions to another friend and studied drawings again after getting a reply. Also reviewed additional drawings for wiring routing information and for control cables.

Shopped for battery chargers for the PC680 main battery and the TCW backup batteries. I plan to order the main battery and a single backup battery and their chargers to use during testing of avionics wiring.

Started working with wire spreadsheet to figure out how to use pivot tables to provide wire counts and lengths. Considering manual entry by wire number.

  Mar 07, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics

Called Van's Builder support with questions. Emailed the Van's kit group to get a packing list for a firewall forward kit so I can get some of the components on order.

Updated the wire list and schematic to change from EI commander to Engine Bridge for E-Mag control and monitoring.

Printed two sets of instrument panels and labels and worked on new layouts.

  Mar 06, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics

Worked on panel layout. Made some changes to some of the labels so I could arrange them differently.

Worked on schematic and wire list changes. Changed from a Guardian CO detector to a Flight Data Systems GD 40. Ordered the GD 40.

  Mar 04, 2023     Avionics and Electrical - (5.6 hours)       Category: Avionics

Met the weekly goal with a total of 32.1 hours.

Made a few final changes to the panel layout draft and sent a picture to a friend asking for review.

Finished paper templates for other components that need to be installed near the panel and started looking for places for them.

Started updating the schematic and wire list with the changes I made during panel layout.

  Mar 03, 2023     Avionics and Electrical - (4.3 hours) Category: Avionics

Reviewed Garmin email about second GEA 24 limitations. Reviewed CO Detector and Engine Bridge documentation. Made final decision on CO detector (Flight Data Systems GD 40) based on lifetime, G3X serial connectivity and remote mount allowing easy future change without impacting panel design if needed.
Made final decision on E-Mag monitor and decided to use Engine Bridge with Wi-Fi instead of analog signals.

Continued work on locations for Avionics on the bulkheads behind the panel. Created a few more solid models and imported solid models into Solidworks assembly to get an idea of component fit.

  Mar 02, 2023     Avionics and Electrical - (5.4 hours) Category: Avionics

Continued work on labels. Made new labels for missing or changed items. I think my work is ready for review and feedback.

Started working on position for other components. Created SolidWorks models for TCW IBBS, ACK E-04 alarm module. Imported starter relay model.

Traded emails with Garmin and Aithre about using dual GEA 24s and options for Aithre integration.

  Mar 01, 2023     Avionics and Electrical - (2 hours) Category: Avionics

Started work on where to place the remaining Garmin Avionics. Need to consider space and access. Printed full size templates of the GAD 27, GAD 29 and GDU 460. Probably need to continue with printing templates for other components. I'm creating the templates by doing a screen capture of the G3X Install manual and then scaling to actual size using Inkscape.

Also after looking at the RV in the garage I decided I really need to use the Solidworks models for some of this.

I included a portion of the time I spent looking at different heat shrink tubing marking solutions for wire. I'm leaning towards Epson, but Demo Rhino 4200 or Brady M210 look like they would also work.

  Feb 28, 2023     Avionics and Electrical - (5.7 hours)       Category: Avionics

Continued work on panel layout. Researched control cable options and called McFarlane with questions.

  Feb 27, 2023     Avionics and Electrical - (3.6 hours)       Category: Avionics

Unpacked and inspected Catto Prop. Looks great.

Continued work on panel layout by printing and placing components/labels. Created additional missing labels and modified and reprinted as needed.

  Feb 26, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics

Created or updated inkscape labels for ELT, Master Switch, Circuit breaker, TOGA switch, Dimmers, group of ignition switches and K2 switch. Created groups of power and lighting switches with labels.

  Feb 25, 2023     Avionics and Electrical - (6.9 hours)       Category: Avionics

Met weekly goal by working a total of 13.8 hours instead of the minimum of 13.5 hours.

Updated sample labels to use round corners. Found out the file formats I used for the panel layouts and labels wouldn't print. Converted files and figured out scaling. Printed layouts with G5 to the left and to the right of the centerline. Also printed labels. Cut up prints and sat in airplane to try various configurations. I decided I like the G5 on the left of centerline and continued to place switches in various locations. I included a picture of the one I liked.

Updated Solidworks G5, center stack and GDU locations to match the desired location.

Unpacked and inspected electrical parts order from B&C.

Downloaded and opened the solid model for the Clippard alternate static port.

  Feb 24, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics

Discussed EX 3.0 CO detector with Aithre.

Modeled fuse blocks in Solidworks and created a Fuse Panel Assembly.

Worked on High Level Panel layouts and created a file to print a full size version for testing. One has the G5 left of the center support and the left edge of the center stack radios aligned with the left edge of the G5. The other has the G5 to the right of the center support and the right edge of the center stack radios aligned with the right edge of the G5. Both include the GDU 460.

Worked on several examples of switch layout and text using inkscape. Created several options to print for testing.

  Feb 23, 2023     Avionics and Electrical - (.2 hour) Category: Avionics

Sent question about using multiple GEA 24s to gain an additional 7 analog input ports.

  Feb 22, 2023     Avionics and Electrical - (1.2 hours) Category: Avionics

Back from a great trip visiting the grandkids...

Reviewed B&C catalog and shopping cart I had built. Added and deleted parts and placed the order.

Started research on the Aithre product line and CO Detector after reading about them in Aviation Consumer. May switch to their CO Detector to save panel space, allow G3X logging of data, use of their IOS app and potential for expansion to their oxygen system.

  Feb 13, 2023     Avionics and Electrical - (5.2 hours) Category: Avionics

Met my goal for another week since I will be out of town for the rest of the week. I hope to get some work done during the week, but the goal of the trip is to spend time with kids and grandkids!

Continued work on spreadsheet to clean up connections and figure out best locations for devices based on number of connections between devices.

Talked to panel shop about the questions I had on stiffness of the overall panel and the fuse panel mounting.

Created solidworks drawings showing keep out areas on the panel and potential locations for the G5 and other radio stack items.

Talked to B&C about deleting the alternator field switch and confirmed it was reasonable since I have a pull-able breaker to use to disable the alternator for testing or emergencies.

  Feb 12, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics

Matched up fuse count of the schematic and spreadsheet. Decided on type and sizes of fuse and updated cart for the next B&C Specialty order.

Archived revision 2 of the schematic and corresponding spreadsheet and started revision 3.

Completed several more potential layouts of the G5 and center stack and printed views with key dimensions to share with the panel shop.

Not included in the time: Printed revision 2 of the schematic and a copy of all the sketches for the panel shop.

  Feb 11, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics

Exceeded time goal for another week. 32.7 hours instead of just 31.5.

Continued work on making some final decisions that affect the panel design and organizing material to had off to the designer.

Inspected parts from Digikey.

  Feb 10, 2023     Avionics and Electricalcs - (3 hours) Category: Avionics

Continued work on spreadsheet and schematic. Mostly worked on adding power connections and information. Starting creating dataset to hand off panel design and fabrication.

Not included in time: Visited Superior

  Feb 08, 2023     Avionics and Electrical - (4.6 hours) Category: Avionics

Continued work on spreadsheet and schematic. Corrected a problem with the ground and switch symbols on the schematic so the BOM now has an accurate summary count of switches and grounds.

  Feb 07, 2023     Avionics and Electrical - (4.9 hours)       Category: Avionics

Continued work on the spreadsheet and schematic. Cleaning up labels and adding wire gauge information. Cleaning up the devices listed in the spreadsheet by adding missing ones and deleting some I am no longer using.

Not included in time: Discussed panel design and options with John H. Received FedEx delivery of Catto Prop. Didn't open the box yet.

  Feb 06, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics

Researched diodes to use for Diode-Or power connections to the GTR200B and GNX375 (second connector).

Reviewed Digikey, Mouser and Stein Air carts, made some updates and placed orders.
The Mouser order included K1 and K2 panel switches, the key switch (master), relays for the small starter switch on the stick, diodes for the solenoids and relays and resistors.
The Digikey order included limit switches for flap position, a connector for the wires going to the pilot and copilot stick, diode-or dual diode packs, QC terminals (.187 and .110) and a isolated music input jack.
The Stein Air cart included a mounting bracket for the GMU 11, a defrost fan and grill, headset and mic jacks, the field circuit breaker, an LED strip light and a pitot static toggle valve for alternate static.

Continued update of schematic and spreadsheet.

  Feb 05, 2023     Avionics and Electrical - (6.8 hours) Category: Avionics

Continued work on spreadsheet and schematic. Continued to add wire sizes, labels and shield connection and wire types to both. Added part numbers to many of the parts. Generated a BOM from the schematic to count switches, resistors and diodes.

  Feb 04, 2023     Avionics and Electrical - (8.7 hours) Category: Avionics

Barely exceeded my weekly goal of 31.5 hours with a total of 32. But I was out of town most of two days so not bad.

Still working on the spreadsheet and schematic. Also adding parts to my Mouser, Digikey and Stein shopping cart and planning to place an order soon. Waiting for my Catto prop to be delivered. It was delayed by the bad weather last week.

  Feb 03, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics

Continued updating schematic and wireless with wire names. Changed fuel pump to use fuse. Discussed fuses and EI commander with Brad at EMAG and updated schematic to use fuses for Emag power. Researched and found isolated jack for music input.

Not included in time: Picked up spinner, backing plate and crush plate weight from Michael's (UPS shipment from Catto Prop).

  Feb 02, 2023     Avionics and Electrical - (6.1 hours) Category: Avionics

Continued updating schematic and spreadsheet and adding wire names and types.

Talked to Tosten to get switch ratings. Researched and selected a relay for the starter switch in the Tosten grip.

Researched and selected limit switches and related parts for flap motor up and down limits.

  Feb 01, 2023     Avionics and Electrical - (6.2 hours) Category: Avionics

Continued work on schematic and spreadsheet.

Updated Revision 2 schematic with changes.
Deleted horn and beacon.
Changed Fuel Pump power to use fuse and added diode to fuel pump.
Changed master switch circuit to use a single keyswitch.
Added starter enable button, relay, diode and connection to pilot stick.
Increased wire gauge on battery connections and changed to brass strip between contactors and between contactor and ANL.
Starting updating wire gauges, wire labels, and adding shield information.

Started updating the schematic and adding wire gauges, wire labels and adding shield information. Making sure schematic and spreadsheet match as I go.

  Jan 31, 2023     Avionics and Electrical - (2.2 hours) Category: Avionics

Traveled home a day early due to winter weather warnings and need to be home when my prop is delivered. The trip was quick since not many people were on the road and we picked a time where it wasn't raining/sleeting and was just above freezing. Arrived home at 4:15PM so another day off, but decided to get some work done anyway.

FedEx still shows delivery of my prop Wednesday (tomorrow). But there is also a general FexEx warning about weather delays. And my prop is still showing in transit to or located in Flagstaff.

Updated Solidworks document to add a switch for Pitot heat and two spares.

Imported Larry's dxf and AI into Solidworks to try to see what was in it. Tried exporting Solidworks into dxf to understand what was possible. Imported Van's dxf into Solidworks. I am learning, but none of that seems too promising.

Downloaded Inkscape (open source program similar to Adobe Illustrator) and started figuring out how to use it. I think this will work to create the graphics file I need.

Figured out how to take the Van's 3D model of the front panel and unfold it. This will allow me to increase the panel height if I decide I need it.

  Jan 30, 2023     Avionics and Electrical - (.2 hour) Category: Avionics

Traveled to San Antonio this morning so a day off.

Read VAF postings and traded PMs with Larry about using a mechanical CAD package and Adobe Illustrator for panel layout and labeling. Read his December 2022 Kitplanes article.

  Jan 29, 2023     Avionics and Electrical - (6.2 hours)       Category: Avionics

Continuing work on the panel layout. Finished creating sub panels for the switch groups and a model for the ELT remote panel. Placed everything on the panel except for the pitot heat switch, cutout for fuse access, and the iPad mount. I'll need to move some things around. At least this shows I should be able to fit everything in the panel.

  Jan 28, 2023     Avionics and Electrical - (4.4 hours)       Category: Avionics

Met my weekly goal of 31.5 hours. Actually worked some every dat for a total of 35.9 hours.

Continued work on panel layout. Created a model for the Klixon 7277 circuit breaker. I am still learning new things about Solidworks. Cleaned up a rough panel I had started by removing components from the panel and placing and defining position one by one. The center stack component are now grouped together and can be moved up/down or right/left with one dimension change. I am creating sub-panels with switches grouped together so I can add them to the main panel and move them around easily. Also worked with adding labels and decals in Solidworks and think I need to use a different program to create them.

  Jan 27, 2023     Avionics and Electrical - (4.3 hours) Category: Avionics

Continued work on panel. Downloaded cad models from Otto and Apem and imported them into Solidworks.

Reviewed recent service bulletin. Looked at avionics bay access panel kit. Looked at Van's firewall forward kits. Starting a list of questions for Vans Support.

Looked at availability of lighted Otto K1 switches and found a couple that were special order. Decided to use unlighted switches.

  Jan 26, 2023     Avionics and Electrical - (1.8 hours) Category: Avionics

Continuing work on panel. Sketched ideas for grouping and labeling switches.

Emailed questions related to wiring and panel labels to AFP, Emag, Oplite and TWC.

  Jan 25, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics

Worked on the panel layout some more. Moved the center stack 3" to the right to provide more space for switches. Cleaned up list of questions and topics to discuss with Brian.

Summarized notes from meeting with Brian. Created the guardian CO detector and EI commander parts for the panel layout.

Not included in the time: Met Brian for lunch, looked at his beautiful RV-7, and asked a lot of questions. Brian provided tips, ideas and reviewed the schematic.

  Jan 24, 2023     Avionics and Electrical - (8.1 hours)       Category: Avionics

Finished final review of Revision 1 of schematic and spreadsheet. Changed some colors and cleaned up the schematic some. Created PDFs to take to FedEx to print. Saved copies of all Revision 1 documents and started Revision 2 for any future changes.

Started work on on panel layout using SolidWorks. Created parts for the GSB 15 and K1 and K2 switches. Imported all the other Garmin and Van's Aircraft parts. Started creating top assembly. Discovered the hole in the center of the panel is not really in the center. See the attached prints for the initial rough layout.

Inspected and logged Mouser parts including 1)Otto K1 flap, SPST and SPDT. 2) Otto P3 pushbutton starter and horn. 3)And a few other parts.

Not included in the time: Trip to FedEx to use their large format printer to print revision 1 of the schematic.

  Jan 23, 2023     Avionics and Electrical - (8.9 hours) Category: Avionics

Continued working on schematic and wiring spreadsheet. Completed first complete pass through all items on the spreadsheet and the schematic. Added switches and power and ground connections to the schematic and spreadsheet as needed. Still have some open questions to discuss with other builders, but the initial plan is documented. Next steps:
- quick review and cleanup to make the schematic easier to read and then print a copy and send to others for review (1/24)
- need to complete panel layout including switches to verify I have room for the parts in the current design or if I need to revise it to use fewer switches.
- need to complete determining wire size and type and shielding connections (future).

  Jan 22, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics

Continued working on schematic and wire list. Started adding connections for power distribution. Added PMAG, fuel pump and alternator field circuit breakers and connections. Added more devices and switches. Added connection information for IBBS.

  Jan 21, 2023     Avionics and Electrical - (8.3 hours) Category: Avionics

Met my weekly goal of 31.5 hours. Actually worked some every dat for a total of 44.3 hours.

Continued work on schematic and wireless. Added some lights and switches. Researched and selected push button switches for the starter and horn. Looked for shrouds to protect the start button. Added connection to GAD 027 discrete to monitor fuel pump.

  Jan 20, 2023     Avionics and Electrical - (7.2 hours) Category: Avionics

Continued work on schematic and spreadsheet. Finished most signal connections except power, CAN bus details, lights and switches. Started working on power and switches. Still need to finish that and add wire types and more wire labels and shielding information.

Researched starter types and circuits. Added a sensor connection to the starter to detect starter activated.

  Jan 19, 2023     Avionics and Electronics - (3 hours) Category: Avionics

Continued work on schematic. Created flap and toga switch symbols and added to schematic. Researched switches and alternator field wire test points. Added other connections to schematic.

  Jan 18, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics

Continued work on the schematic and wire list. Added and started connecting GTR 200B, Jacks, Dimmer switches, flap and trim motors and stick grip switches to the schematic. Continued work on the GEA 24 and GAD 27 parts. Verified connections on the spreadsheet and updated spreadsheet and schematic symbols as needed.

  Jan 17, 2023     Avionics and Electrical - (8.8 hours) Category: Avionics

Continued work on schematic. Adding connections on schematic and checking against the spreadsheet. Updating symbols and the spreadsheet as needed. Except for power and ground connections and showing shielding on wires, completed pin connections on G5, GAD 29, ELT, GAP 26, GDU 460, GMC 507, GMU 11 and GNX 375. Sent question to Garmin about GNX 375 power connections. Completed GEA 24 J242 connector and reworked thermocouple symbols to fit better. Created connector symbol for OLC-2 connector. Started GEA 24 J244 connections.

Created 4 symbols for showing shielded wire (single wire, twisted pair, three wire and four wire).

  Jan 16, 2023     Avionics and Electrical - (6.9 hours) Category: Avionics

Sent payment to Catto Propeller for my prop. The prop should be delivered in early February.

Sent question to Lycoming about engine configuration. I'm hoping the change to AFP fuel injection was made in time to be installed on my engine. I haven't heard any schedule updates since Van's told me Lycoming would ship on 4/11/2023.

Continued working on schematic and wire list. Completed pin connections for RS-232 and ARINC signals. Worked on CO Detector, EI Commander and Emag ignition pin connections.

Found and fixed a few more problems with the wiring spreadsheet.

Researched circuit breaker options after determining I should use circuit breakers instead of fuses for the EMag electronic ignition power since ATC fuses are not available in slow-blow.

  Jan 15, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics

Continuing work on schematic. Added new Garmin symbols to sheet two and started working on interconnects. Created configuration module symbol. Started experimenting with options to use buses and labels for RS-232 connections. Tried a few work arounds for showing shielded wire and decided I need to create some new shielded wire symbols in Solidworks.

Completed clean up of wireless and imported into Numbers from Excel. Now I can work on the wireless, schematic and look at supplier documentation all from the MacBook.

  Jan 14, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics

Continued work on the schematic. Added symbols for seat heater, horn, jack for testing, FlyLEDs lights and controller, flap and trim motors and position sensors, lights for map, glare shield, and baggage area.

Started cleanup of wirelist spreadsheet. Moved circuit protection and current information from main tab to the LRU tab. Explored options using vlookup for documenting wire label text, size, type and length since I have each connection listed twice in the spreadsheet. I and ended up deciding to simplify and just enter the wire label text, size, type and length for the first connection and using the wire label text only for the second connection.

  Jan 13, 2023     Avionics and Electrical - (2.8 hours) Category: Avionics

Continued work on schematic. Created symbols for GAP 26, Antennas (NAV, COM, COM, XPDR, GPS, GPS), ELT, Music Jack, CO detector, EI Commander, Fan and fuel level sensor.

  Jan 12, 2023     Avionics and Electrical - (5.4 hours) Category: Avionics

Continued work on schematic. Reworked GSA 28, GNX 375, and GEA 24 symbols. Reworked GEA 24 to split out each connector into a separate symbol. Added symbols for G5, EGT, CHT, fuel flow, oil pressure, fuel pressure, manifold pressure, oil temperature, headset jack, microphone jack and pilot and copilot stick grips.

  Jan 11, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics

Continued work on schematic. Realized the symbols I created with the pins in order would look confusing on the schematic. Reworked GRT 200, GAD 29, GMC 507, GAD 27 and GDU 460 to group pins by function. Reworked GAD 27 to split out each connector into a separate symbol.

  Jan 10, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics

Continued work on schematic. Created symbols for GAD 27, GAD 29C, GDU 460, GEA 24, GMC 507, GMU11, GNX 375, GSA 28, GSB 15, GTP 59 and GTR 200B.

  Jan 09, 2023     Avionics and Electrical - (4.2 hours) Category: Avionics

Continued work on power distribution portion of schematic. Created Hall Effect and several switch symbols.

  Jan 08, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics

Started phase 3 commitment. Worked on power distribution schematic and creating symbols for components. Tried several different power distribution layouts. Created ground block and electronic ignition symbols. Realized the battery, contactors, fuse, starter and alternator symbols were too large so recreated them.

  Jan 07, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics

Continued work on symbols for schematic. Figured out how to sketch symbol graphics in Solidworks and import into the symbol library and add information and pins. May have completed symbols for Main/Battery Switch, Starter, Alternator, Battery Contactor, Starter Contactor, Fuse and Battery.

  Jan 06, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics

Back at it again after a break to enjoy Christmas and New Year's Eve with family.

Started creating symbols that I need for the power distribution schematic. Completed a family of fuse boxes. Using square boxes for contactors, Alternator, Battery and Main/Start switch and don't like it. Needs to be more graphical so you don't have to read details to understand the big picture.

  Dec 24, 2022     Weekly update Category: Avionics

I missed my goal this week. I was supposed to work an average of three hours a day for Sunday, Monday, Tuesday and Wednesday and didn't. My daughter and her family arrived Thursday for Christmas and I'm treating 12/22 through 12/31 as holiday from building.

Phase three of my commitment runs from 1/8 through 4/8 and I'm increasing the average daily time from 3 to 4.5 hours. The major focus will be on finishing wiring and testing of the panel.

  Dec 20, 2022     Avionics and Electrical - (2.1 hours) Category: Avionics

Continued working with KiCad. Tried using multiple sheets and sizing each sheet differently. The second and fourth sheet seemed linked. When I changed the size of one of them the other changed. Tried again later and had a problem using sheet 4. Maybe sheet 4 is the problem or maybe I don't know how to use it.

Tried using hierarchical labels and global labels to understand how to use them and figure out which one works best for me.

  Dec 19, 2022     Avionics and Electrical. - (2 hours) Category: Avionics

Worked with the first symbol on several sheet sizes to see how things would look and how much I could put on each sheet. Looked at examples to see if I liked how others had created schematics. I plan to use at least a C sized sheet and possible a D sized sheet. I think an E sized sheet will be too difficult to handle and I don't plan to use it. Watched more tutorials on using multi-sheet schematics and the two ways to organize them.

Added a LRU column to the wiring spreadsheet and used a pivot table to see connections between different LRU pairs. I was surprised to see how few connections there were between boxes. This will help me know how to place LRUs in the airframe and on the schematic pages.

  Dec 18, 2022     Avionics and Electrical - (4 hours) Category: Avionics

Watched and practiced the schematic portions of the KiCAD tutorials. Started building Garmin symbols and ran into a problem with creating box graphics on the new symbols. Researched and found the bug was fixed in a later version. Upgraded and confirmed I could complete a symbol.

  Dec 17, 2022     Avionics and Electrical - (9.2 hours) Category: Avionics

Met my weekly commitment again, barely. 21 hours over 7 days. I would not have spent as much time yesterday and today if I had not committed to 21 hours a week so making a commitment to my grandkids helped me.

Continued work on the wiring spreadsheet. Worked through most of the signal connections. Need to work on finalizing power and switches next. Creating a list of questions to ask and things to look for the next time I visit an RV builder.

  Dec 16, 2022     Avionics and Electrical - (4.7 hours) Category: Avionics

Continued work on the wiring spreadsheet. Spent most of my time on GEA 24 and GAD 27 and related components and research. Found a nice dimmer switch and plan to order them soon.

  Dec 15, 2022     Landing Light Mounts - (.5 hour) Category: Avionics

Removed landing light mounting plates from the wings at the hangar today. Also made measurements to help with pitot location and wire lengths to pitot and autopilot roll servo.

  Dec 14, 2022     Avionics and Electrical - (4.8 hours) Category: Avionics

Started out looking at GEA signals on the wiring spreadsheet and GEA configuration settings and options.

I'm trying to decide if I should use Gigaflight CAN bus cable as recommended in the G3X documentation even though wire size is 24 instead of the Garmin recommended 22 AWG minimum. The other option is to use the shielded twisted pair that is also recommended by Garmin that has the 22 AWG wire. While looking at cable size I noticed I had selected the wrong type of solder sleeves. Spent time researching the correct solder sleeves, d-sub tools, AFM8 and positioned settings, splice sizing and CAN bus recommendations in the Garmin documentation, on VAF and on Garmin youtube channels.

  Dec 11, 2022     Avionics and Electrical - (1.8 hours) Category: Avionics

Continued working on the wiring spreadsheet. Continuing with the GEA 24 and associated components.

  Dec 10, 2022     Avionics and Electrical - (6.9 hours) Category: Avionics

Met my commitment for another week. 21.2 hours over 7 days. I was thinking I was on a roll and would not need to make a commitment in 2023, but you can tell from my tracking spreadsheet that I am just barely making my commitment and I know there are lots of times I would have skipped working on it except for the commitment.

Continued working on the wiring spreadsheet. Continuing with the GEA 24 and associated components. Spent time trying to understand which pressure sensors I have and which ones were the older versions that had leak issues.

  Dec 09, 2022     Avionics and Electrical - (6.5 hours) Category: Avionics

Continuing work on the wiring spreadsheet. Except for power, CAN and lighting bus, working through all signals one device at a time. Finished GAD 29 and GNX 375. Finished GDU460, G5, GSU 25, GMC 507 and working on GEA 24.

  Dec 08, 2022     Avionics and Electrical - (3.8 hours) Category: Avionics

Updated wiring spreadsheet with all RS-232 and ARINC 429 connections using the responses from Garmin and the example spreadsheet. Working on finalizing all connections for the GAD 29 and GNX 375.

  Dec 07, 2022     Avionics and Electrical - (4 hours) Category: Avionics

Reviewed response on GDU, G5, GNX 375 questions and sent thank you note. All interconnect questions are resolved. Started review of example schematic and wiring spreadsheet and starting to make changes per Garmin response. Researched a few devices and connections on the example schematic that I may want to use.

Found there was a new revision of the G3X Touch install manual (AQ) and reviewed all changes. The most useful new change was additional information on the GAP 26 pitot mount installation.

  Dec 03, 2022     Avionics and Electrical - (5.8 hours) Category: Avionics

Getting back on track. Met my weekly commitment again. 3.1 hours per day for 4 days.

Continued work on RS-232 and ARINC connections document, studied manuals more and sent the remaining open questions in a different format to Garmin. I'm still confused, but understand my questions better.

Added all the Garmin serial numbers to my Garmin parts spreadsheet and entered them into a Garmin website to confirm they were correct. Need to call Garmin before submitting all of them.

Worked with Gigaflight CAN bus cable to verify the acceptable solder sleeve size and started practice with stripping the cable for solder sleeves and splices.

  Dec 02, 2022     RS-232 and ARINC - (4.2 hours) Category: Avionics

Reviewed Garmin reply to my connections questions and started review of documentation and example schematic from Deene to make sure I understand the Garmin reply. Started draft of "RS-232 and ARINC Connections and settings R1". This is all starting to make sense now.

  Dec 01, 2022     Follow up and supply BOM - (2.2 hours) Category: Avionics

Back to it after a long break for a 11/8 to 11/17 trip to see the grandkids that got extended to 11/29 due to Covid. I missed one week of my commitment and sent $50 to my daughter.

Followed up with Aircraft Spruce on pitot install kit. Followed up with Brad at Garmin on connection questions.

Reviewed Aircraft Spruce orders and created spreadsheet with wiring supplies and Garmin equipment. Reviewed Skygeek order and added parts to the wiring supply spreadsheet.

  Nov 07, 2022     Panel Design - (2.1 hours) Category: Avionics

Spent 2.1 hours importing Garmin and Van's models into an assembly and learning trying different methods of import, export, and mating surfaces to do what I need. The training helped.
Also spent more time getting an annual license and trying 3D experience on the macBook.

  Nov 05, 2022     Training Category: Avionics

Spent 0.7 hours watching the final intermediate level parts project. Haven't been working through the details since I won't need to do any of these things for the panel project.

Managed to spend 21 hours this week. I need to get out of training mode and back into completing the wiring spreadsheet and building a panel model and figuring out how many switches I need. Also I found a reply from GigaFlight about the CAN bus cable so I need to make a sample splice in the cable I bought from Aircraft Spruce to confirm it will work for me, then figure out the rough length and then place an order.

  Nov 04, 2022     Training Category: Avionics

Spent 3 hours reviewing more intermediate level part videos. I didn't spend time practicing because most of the tools and commands shown won't help me in laying out the panel. I did want to see them all just in case. The next step is the intermediate final part project.

  Nov 03, 2022     Training Category: Avionics

Spent 3 hours continuing Solidworks training. Completed assembly practice, watched drawing videos and practiced. Started intermediate level parts videos.

  Nov 02, 2022     Training Category: Avionics

Continued SolidWorks training for another 3.8 hours. Practiced by creating another version of the the beginner level final part project. Submitted comments about an error in the video. Watched all the beginner level assembly training and worked on the assembly final project before watching the final video. Need to work through the assembly project one more time before moving on.

  Nov 01, 2022     Training       Category: Avionics

Spent 3.4 hours on training today. Watched Aryan build the beginner level final project part to see how his approach was different than mine. Then started from scratch and built the project much more quickly. Starting to learn how to find my way around and create and fix things. I'm going to do the project one more time tomorrow before moving on.

The attached picture is the solid model I created from a 2D drawing. It doesn't look like an instrument panel, but I learned a lot of basic solid works skills in the process of creating it.

Tried panel planner again after getting some responses from Gene. I may be working with him tomorrow.

  Oct 31, 2022     Training Category: Avionics

Working on the beginner level parts final project for 7.1 hours. It is taking a while and it is good practice.

  Oct 28, 2022     Training Category: Avionics

We are headed out of town Saturday so this is the last entry for this week. It has been a short week with a two day trip to Dallas for a funeral and the trip tomorrow to see family. I've completed 12.3 hours of training for the 4 days home so slightly exceeded my goal of 3 hours a day.

Today I spent 0.2 hours watching the last few beginner level training on parts. The only one left is the final project for beginner level parts to see if I really learned it and to see a few new tips.

  Oct 27, 2022     Training Category: Avionics

Continued training for another 0.8 hours. Couldn't do much since we were leaving town for a funeral in Arlington, TX.

  Oct 26, 2022     Training Category: Avionics

Spent 4.3 hours continuing SolidWorks training. I'm learning a lot.

  Oct 25, 2022     Panel Design - training Category: Avionics

Monday, 10/24, I spent about 1 hour looking at sample solid works training and sent questions to Aryan at Solidworks Course Pro. Today I signed up for the Lite Course and spent 3.5 hours going through online courses and practicing. I'm counting this time against my 3 hours a day commitment to RV building, but not logging the time in this formal builders log.

The Solidworks Pro Course is great so far.

  Oct 23, 2022     Panel Design - (2.5 hours) Category: Avionics

Started looking for tutorials for solid works. Found solidworkstutorials.net SolidworksCoursePro and watched the introduction, top 10 mistakes and first 5 free videos. I'm trying to decide on whether to sign up for the full or lite course. I've already learned quite a bit just from the demos.

  Oct 22, 2022     Panel Design - (3.8 hours) Category: Avionics

Worked on RV things for 21.2 hours this week. Did miss one day when I just needed a break. The commitment to average 3 hours a day is helping. I would have skipped more days and not worked on it as much.

Spent a little more time with hangarflying.com panel designer and decided it isn't what I want.

Started looking at Solidworks 3D experience and bought a month long license. Set it up for use on my macBook and a PC. Installed Solidworks on the PC. Was able to import the Van's panel iges file and also the Garmin GDU 460 step file. Now I just need to figure out how to use Solidworks.

  Oct 21, 2022     Panel Planner - (6.2 hours) Category: Avionics

Started using panel planner. The goal was to update my original draft to match the Garmin equipment I selected and to lay in all the switches to see how much room I had and how they looked. I started using the application and ran into problems and reported them. And when I started to create switches in panel planner I ran into more problems. We had a long meeting so I could show them what I was doing and seeing. They plan to work on it and created and added the switches for me.

I started using the new switches and found another issue and reported it.

The good news is I started work on the switch layout using the panel planner. The bad news is I didn't make much progress. I'm really frustrated.

Started looking at alternates to panel planner.

  Oct 20, 2022     Avionics and Electrical - (3.5 hours) Category: Avionics

Skipped a day yesterday. I did spend some time cleaning up my office working area organizing the Garmin parts, tools and supplies and clearing my workbench.

Fired up panel planner looked for switches and some other parts. Remembered why I don't like it.

Searched for, read and downloaded Carling Tech and Otto switch information. Worked on switch groupings and compared size and features of different switch series.

Received an email today from Van's saying Lycoming expected my engine to be ready 4/11/2023. Yay! Great timing. I was hoping for March or April.

  Oct 18, 2022     Avionics and Electrical - (3.1 hours) Category: Avionics

Continued work on wiring spreadsheet and wiring design. Discussed TCW IBBS connections and function with TCW tech support. Discussed how modern avionics and TCW, in their opinion, obviates (new word of the day!) the need for the endurance bus. Decided to change my approach to match the TCW recommended approach which is also shown in the Garmin install manual.

Looking at how many switches I have on the panel and how many I can combine...

  Oct 17, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics

Continued work on the wiring spreadsheet. Added more starter, regulator and alternator parts and lines.

Discussed switches, circuit breakers/fuses and wiring with Deene. Studied an avionics schematic for a Garmin G3X/G5/GNX375 configuration that is similar to mine.

  Oct 16, 2022     Avionics and Electrical - (1.5 hours) Category: Avionics

Completed renaming LRUs and all the places where the LRU names were referenced. Did a quick v-lookup and identified all the LRUs that were missing from the main data tab and added all of them. I'm starting Revision 15 of the spreadsheet now.

  Oct 15, 2022     Avionics and Electrical - (5 hours) Category: Avionics

Just reached my weekly goal. I was out of town three days so only needed 12 hours. Researched and downloaded data sheets on Otto and Carling Switches. Planned to use progressive switches for several functions to reduce switch count.

Visited Luis again at Breakaway Airport to look at the panel again and ask some switch questions. He didn't use any progressive switches. I liked the simplicity and clear on/off labels on the Otto K1 and K2 switches. Didn't include any time at Breakaway in the daily time. May change back to simple on/off switches. Will know after I get a final switch count and try them on a new panel layout.

Continued work on the wiring spreadsheet. Added the "always hot" fuse block. Eliminated some columns on the LRU tab. Renamed many of the LRUs to eliminate extra "-1"s and make naming more consistent, Started modifying the main data tab to use the new LRU names.

Researched engine bridge which is an alternative to EI commander.

  Oct 14, 2022     Avionics and Electrical - (.5 hour)       Category: Avionics

Made, installed and tested new jumper wires between the strobe/position light PCBs. FlyLeds recommended just stripped wires with no ferrules due to space limitations. They seem to work well.

  Oct 13, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics

Continued work on the wiring spreadsheet. Added seat heaters and investigated seat heater options. Changed 12V outlet currents and may eliminate them. Added second USB port in baggage area.

  Oct 10, 2022     Avionics and Electrical - (1 hour) Category: Avionics

Bus maximum currents exceed alternator capability so started reviewing data. Added current column to show max currents excluding intermittent loads such as flap, autopilot servo and trim loads. Adjusted assumption on pitot heater. Reviewing other power data and rethinking decision to add power outlets and only one USB outlet.

Reviewed and downloaded Stratus 3 data.

  Oct 10, 2022     Avionics and Electrical - (3 hours) Category: Avionics

Continued work on wiring spreadsheet. Added two fuse blocks and deleted individual fuses. Completed first pass of listing fuses, max current and typical current for all devices. Completed identifying which devices connect to each of the battery backups. Created a pivot table showing fuse counts on the main and endurance bus and total currents for the main, endurance and two battery backup buses. Updated autopilot power schematic. Started looking at details of the battery, starter, regulator and alternator circuits.

  Oct 08, 2022     Avionics and Electrical - (5.5 hours)       Category: Avionics

Met goals for another week. 26.1 hours which is more than the 21 hour commitment. Missed working on the project one day, but more than made up for it on other days.

Continued work on wiring spreadsheet and figured out final format for showing fuse sizes, max current and typical current. Searched through Van's docs, VAF and Ray Allen docs and FAQs to find flap and trim motor currents.

Searched through Garmin docs for CAN bus and wiring notes and summarized in wiring spreadsheet.

Sent quote request to Gigaflight CAN bus wire to see if they sell it cheaper than Aircraft Spruce ($6.50 per foot).

Inventoried single wire size and shielded wire already on hand. Found bags of ferrules and marked with AWG size. Made up 4 individual interconnect wires with ferrules and replaced the ribbon cable jumper and sent pictures to FlyLeds for comment. The ferrules are touching some of the power resistors.

  Oct 07, 2022     Avionics and Electrical - (6.2 hours)       Category: Avionics

Looked through Aeroelectric schematics and printed several schematics for markup. Printed Z-11P on tabloid sized printer for markup. Looked up D-Sub connector information and added summary to spreadsheet. Continued working on wiring spreadsheet.

Worked on lens for right wingtip and cut out clearance hole in wingtip for light board parts. Used dremel tool with cut-off wheel and permagrit files. Still need to work on one half of the lens.

  Oct 06, 2022     Avionics and Electrical - (4.6 hours) Category: Avionics

Continued working on power and ground signals on the wiring spreadsheet.

Downloaded and saved install manuals as I went to build a document library for this RV.

Created spreadsheet tables for 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22 and 24 AWG wires. Each table shows voltage drops for currents of 1 to 30 amps and wire lengths from 1 to 30.

Marked up existing Garmin and FlyLed docs to create 4 rough looking schematics to go along with the wiring spreadsheet. I'll create clean and complete schematics after I wire and test the design.
Power, Backup
Power, Autopilot
Lights, Position, Strobe
Lights, Taxi, Landing

  Oct 04, 2022     Avionics and Electrical - (1.8 hours) Category: Avionics

Continued working on power and ground signals on the wiring spreadsheet.

  Oct 03, 2022     Avionics and Electrical - (4.5 hours) Category: Avionics

Continued work on the wire list spreadsheet. Added more devices and columns. Started adding information on power sources and fuse sizes.

Reached out to Aircraft Spruce to add the fine version of permagrit files to my order and ask about the status of the pitot install kit which seems to have been ordered, ordered again, canceled and previously shipped.

Looked up more options for red beacon lighting. Looked up sizes of fuse blocks and ground blocks available from B&C.

  Oct 02, 2022     Avionics and Electricalcs - (3.5 hours) Category: Avionics

Continued work on the wiring spreadsheet. Added alternator, regulator, ANR and some switches and fuses. Added information about location and one power source. Added seat heaters and looked for seat and heater sources.

  Oct 01, 2022     Avionics and Electrical - (3 hours) Category: Avionics

Barely exceeded my weekly goal of 21 hours by completing 21.7. I did work on it every day. The commitment to the grandkids really helped this week. I got really busy with some non RV stuff and I would have skipped several days and spent a lot less time on some days.

Today I worked on cleaning up wiring spreadsheet and adding information on locations of switches. I need to identify every potential switch and fuse/breaker to complete the panel design.

  Sep 26, 2022     Avionics and Lighting - (3.1 hours) Category: Avionics

Sent status update and list of questions about power distribution to technical counselor.

Placed Mouser resistor, APEM switch and Amploc connector order. Placed Amploc Key100 Hall Effect sensor order.

Started cutting wingtip lighting PCBs with aviation tin snips and filing edges smooth with permagrit files. One set is near final size.

  Sep 25, 2022     Avionics and Electrical - (2 hours) Category: Avionics

Studied Aeroelectric appendix Z power distribution architecture and notes.

  Sep 24, 2022     Avionics and Electrical - (3.5 hours) Category: Avionics

Met my goal of 21 hours for another week. Worked on the project every day. Had expected to work more than the actual 22.7 hours.

Continued working on wiring spreadsheet. I have now looked at and researched at least some of the connections for all the avionics. Spent time today wrapping up details related to CWS/Disc, TO/GA, and Pitot. Also changed fuel sensors to eliminate 2.2K pull-ups since a circuit without pull-ups is sufficient for a metal airplane per Garmin. Researched Glide Activate and decided to just use the G3X Touch interface instead of a dedicated Garmin button.

Researched methods to trim the FlyLEDs and found this helpful website: https://www.youtube.com/watch?v=uBkPX_QhRI0

The next major task on the spreadsheet is to decide on an electrical distribution architecture.

  Sep 23, 2022     Avionics and Electrical - (2.1 hours) Category: Avionics

Searched for flap switch options on VAF and found one at Mouser that should work. Added it to the Mouser cart.

Read response from EI-Commander and plan to wire up the G3X Touch and EI-Commander and e-mag per their guidance.

Searched for panel layout guidelines in VAF and Kitplanes magazine. Got some ideas.

Read about options for power distribution, avionics bus, endurance bus, single bus on VAF.

Picked two Hammond Enclosure boxes that should work with the FlyLeds controller board and added them to the Mouser cart.

  Sep 22, 2022     Avionics and Electrical - (4 hours) Category: Avionics

Reviewed tach signals and associated data sheets. Sent tach signal connection questions to EI-Commander.

Reviewed fuel level schematics and information in G3X touch again and found out I don't need to add the 2.2K ohm resistors.

Also spent time on CWS/DISC and TO/GA signals and researching ideas for which signals to connect to the stick grip. Added TO/GA switch and 5K pull-up resistors to Mouser cart.

Researched flap switch location and types on VAF and started searching for a flap switch.

  Sep 21, 2022     Avionics and Electrical - (2.7 hours) Category: Avionics

Continued work on wiring spreadsheet. Added details for many of the engine and airframe sensors and made connections to the GEA 24. Still more to go.

  Sep 20, 2022     Avionics and Electrical - (3.1 hours) Category: Avionics

Continued working on wiring spreadsheet.

Completed lights and associated connections to GAD 27. Added engine and airframe sensors to spreadsheet and started on GEA 24 Engine Interface connections.

  Sep 19, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics

Continued working on wireless spreadsheet. Started adding GAD 27 connections after adding switches, potentiometers for dimming, trim motors, flap motor and FlyLEDs devices to the spreadsheet.

  Sep 18, 2022     Wiring Spreadsheet - (4.8 hours) Category: Avionics

Worked through all GNX 375 connections and started email to Garmin with several questions.

Added lots of details and devices to the spreadsheet. Lighting control pots, flap switches, headset and music jacks, power outlets, antennas, and added details of pilot and copilot stick grips.

Completed most connections to the GTR 200B VHF COM radio.

Reviewed and completed most of the connections to the GAD 29 except waiting on information before assigning ARINC pins.

Started review of signals and adding connections to the GAD 27 flap, trim and lighting controller.

Opened up all the Garmin boxes and packages to verify the parts looked okay and verify GA 26x antennas came with cables. Didn't check serial numbers.

  Sep 17, 2022     More RS-232, ARINC 429 and other connections - (6.7 hours) Category: Avionics

Met my goal for another week. I was in town the full week so the goal was 21 hours. I actually worked 29.5 hours and worked on it every day. The main accomplishment for the week was making a lot of progress on understanding the system architecture and connection details and figuring out my first guess at all the RS-232 connections. I also received another third of my Garmin Avionics order.

Completed updating the wiring connection spreadsheet with all the RS-232 connections. Reviewed ARINC 429 connections in the manual. Sent a list of assumptions and questions to Garmin for review.

Researched EI Commander on VAF at and the EI Commander website and decided I probably want to include it. Added an EI Commander to the spreadsheet and completed the connections between the E-Mags and the EI commander after studying the installation instructions for both.

  Sep 16, 2022     RS-232 and ARINC - (3 hours) Category: Avionics

Finally things seemed to click. I spent more time with the G3X Touch, G5 and GNX 375 installation manuals. I think I understand all the RS-232 connections and settings. I've updated the wiring spreadsheet with RS-232 connections for the ACK ELT and the TBD CO Detector. I also checked most of the RS-232 connections I made yesterday. I should be able to complete both RS-232 and ARINC connections in the spreadsheet and send my plans to Garmin for confirmation.

  Sep 15, 2022     Garmin G3X Touch, G5 and GNX375 - (5.2 hours) Category: Avionics

Worked on wiring connection spreadsheet. Added CO detector, TCW IBBS battery backup, E-mags and ELT connections. Moved columns around to make it easier to use. Started making entries for RS-232 connections. Spent a lot of time looking at examples and reading details in the Garmin documentation and on VAF and still don't have the RS-232 connections figured out.

  Sep 14, 2022     RS-232 and Audio - (6.3 hours) Category: Avionics

Discussed audio questions with Garmin by email. Got questions from yesterday as well as a new question answered.

Read through G3X Touch, G5 and GNX375 pinout descriptions and configuration information related to serial connections between devices and started documenting RS-232 connections. Searched through VAF for additional information. Making progress understanding the required connections.

  Sep 13, 2022     Audio connections - (1.7 hours) Category: Avionics

Continued research on audio connections between Garmin LRUs and muting. Sent questions to Garmin experts.

  Sep 12, 2022     Avionics - (1.8 hours) Category: Avionics

Started work on pinout spreadsheet focusing on GNX375 connections. Creating list of questions for Garmin.

  Sep 11, 2022     Avionics - (4.5 hours) Category: Avionics

Continued understanding and documenting effects of avionics and power failures. Also looking at overall power structure with main, endurance (avionics) and autopilot buses. Considering using two TCW IBBS systems and identified potential split of critical items. It might be more reasonable to use a single TCW. Started a list of questions for Garmin.

  Sep 09, 2022     Supplies and Tools - (4.8 hours) Category: Avionics

Completed review of materials needed for the G3X Touch installation. Found sources for splices, heat shrink tubing, crimp tool for splices, positioner for high density d-sub contact crimp tool, and insertion/removal tool for high density d-sub contacts. Looked for other parts that will be needed during the build and put some items on supplier wishlists. I know I need a lot more, but won't know more until I finish the design and start building it.

Researched shrink tube wire label options. My contact uses industrial labels which are about $0.60 in bulk. The M23053/5 mil spec labels are 2 or 3 times more. I still have a Kroy printer and a mix of mil spec and commercial labels and will try getting the printer running first.

Unpacked the shipping box and inventoried shipment of Garmin Avionics.

  Sep 08, 2022     Tools and Supplies - (4.5 hours) Category: Avionics

Continued work on Failure modes document.

Started searching for sources for splices and crimp tools for splices.

  Sep 06, 2022     Garmin quote - (.4 hour) Category: Avionics

Reviewed revised quote from Aircraft Spruce and sent one question about the part number for the Garmin autopilot.

  Sep 05, 2022     Tools and supplies - (.4 hour) Category: Avionics

Ordered heat gun kit for solder sleeves.

Decided which solder sleeves would work with the Gigabit CAN cable recommended by Garmin. Placed order for some test parts of three sizes of solder sleeves, a piece of CAN cable and silicone tape for use on the wiring. Also ordered some perma-grit files for use on the FlyLEDs wingtip light boards.

  Sep 04, 2022     Avionics - (.3 hour) Category: Avionics

Drafted and sent email to Aircraft Spruce with quote changes and questions about ordering supplies and Garmin Avionics.

  Sep 03, 2022     Quote review - (.5 hour) Category: Avionics

Completed review and markup of Aircraft Spruce quote.

Met my goal for another week. Was in town 3 full days and averaged 4 hours a day for the 3 days. Also did something related to the project on 6 of the 7 days. This week I made a key decision about what avionics to install and where to buy them. The only day I didn't actually work or research anything was the day we travelled to Camarillo to visit the grandkids. I continued to make a little progress while we were visiting.

  Sep 02, 2022     Avionics - (.6 hour) Category: Avionics

Reviewed Garmin response to my questions about CAN and power failures and was glad to see my assumptions were correct. Started review of the Aircraft Spruce quote to delete and add items. Plan to order Avionics next week.

  Jun 15, 2022     Wiring Spreadsheet - (0.5 hour) Category: Avionics

Added remaining Garmin avionics and control boxes to the wiring spreadsheet.