Dec 08, 2023     Finishing Connectors - (2 hours)       Category: Avionics

Been sick the last couple of days so I didn't get much done.
I did get out today for a couple of hours to finish some stuff that had been delayed while waiting for parts - those parts just came.
Got out and finished the J4602 and J4601 connectors for the GDU 460. Finished the J251 connector for the GSU 25.
Mounted a relay for the Hobbs meter/Low Oil Pressure light - with the relay, the Low Pressure light will be illuminated with the battery master ON until the engine starts and then the relay will turn on power to the Hobbs Meter.

  Nov 25, 2023     Miscellaneous Wiring - (2 hours) Category: Avionics

Today was catching up on some stuff. Finished most of two connectors but have to wait for some ordered items to get in to finish them.

  Nov 23, 2023     GDU 460 - (4 hours)       Category: Avionics

Finally finished the J4601 connector for the GDU 460.
Made all of the connections to the GD-40 CO detector. I still have to connect the LEDs and Test button to the wire that goes to the GD-40.

  Nov 18, 2023     GDU 460 Connector - (4 hours)       Category: Avionics

Spent a whole lot of time and don't feel like I accomplished much. I got most of the wires connected. Still a few more wires to hook up, including the CAN Bus. After this one, just the -25 and individual wires on a few connectors. Not too far to go (on the wiring).

  Nov 16, 2023     GNX 375 Connector - (1 hour)       Category: Avionics

Got out to the shed to finish the J3751 connector. All that was left was to put pins on the Config Module and put it in the D-Sub connector. I did that, put the cover on it, put a couple of zip ties to organize the wires a little better and that one is done.

  Nov 11, 2023     GNX 375 Connector - (4 hours)       Category: Avionics

These connectors sure seem to take a lot of time. This was making the connector for the GNX 375, the J3751. It was actually not too bad to make this one since I was able to do a lot of it out in the open, unlike the GTR 200b connector, the J2001. That one I had to do in the forward fuselage area since the wires were in that area but this one, a lot of the wires originated from the J2001. I have to check and see if I need to put in the Config Module or if the one in the GDU 460 is the only one required. If only the GDU 460 one is required, then the J3751 is complete; if not, then I will have to install the Config Module and then it will be complete.
Also completed the J292 connector - A very easy 4 wire connector.
The other picture is of all of the avionics components and the connectors. The connectors that are highlighted yellow are completed. Encouraging

  Nov 09, 2023     GNX 375 Connector - (1 hour) Category: Avionics

Got out there for about an hour. Looking at the wires needed and what I have - realizing I am short of what I need. Another SteinAir order coming up. That's ok - turns out I need more ring connectors too.
Got the first wire set up to connect. This D-sub takes male pins, not sockets.

  Nov 08, 2023     GTR 200b Connector - (5 hours)       Category: Avionics

This was a long day with what seems like little accomplished. I did manage to connect all of the wires to complete the connector for the GTR 200b. I'm not totally happy with it. Some of the wires are not loose, they aren't excessively taut but I would rather they be looser - but they are good enough and I am not going back and re-wiring the wires, and re-soldering the Capt Mic and Headphone jacks with new wires.
I ended up going back out after dinner and doing a little reworking. I was able to get a little slack in the two wires by rerouting the wires

  Nov 07, 2023     Mic and Headphone Jacks - (2 hours)       Category: Avionics

Realized that the 5-conductor wire to the right side mic and headphone jacks is not shielded. That might be ok but I'm not sure so I replaced that 5-conductor wire with a 2-conductor shielded wire to the mic jack and a 3-conductor shielded wire to the headphone jack. Probably get done sooner if I didn't have to keep undoing work that has been done and re-doing it. I connected those wires to the d-sub connecter. Only a dozen wires to go on that one.
I connected the pilot and co-pilot PTT buttons on the instrument panel.
On another note, the interior arrived today. It looks really good.

  Nov 06, 2023     J243 - (1 hour)       Category: Avionics

With the wires I just got from SteinAir, I was able to finish the J243 connector. I was waiting for a 20AWG 4 conductor wire to connect to the main and Back/up alternator shunts. I ran that wire to the uncompleted connector, put the pins in the D-sub and then put the plate on it. Connected the ground wires to the base and, BAM, another connector is completed. Now all 4 connectors for the GEA 24 are done!
Almost out of time, I hooked up the ground wire to the connector for the GTR 200b. 3 wires are done, only like 2 dozen to go.

  Nov 05, 2023     Got Boxes - (3 hours)       Category: Avionics

While I was gone on a trip, an order from SteinAir was delivered - the black boxes that that make the magic happen have arrived.
I did a fit check and found the GDU 460 had a hole on each side that was slightly off from the nutplate behind it so I had to do a little drilling out. All of the radio stack, the GMC 507 Autopilot, the GNX 375 GPS Navigator, and the GTR 200b Comm Radio, all fit nicely into the holes provided. The G 5 did not go in the hole and I found that I had to cut away some metal from the instrument panel to get it to go in completely.
The GEA 24, GAD 27, and GAD 29 black boxes were mounted in their pre-arranged locations.
Lastly, I connected the wires from the shunts to the GEA 24 J243 connector. Ran out of time to finish the D-Sub connector.

  Nov 02, 2023     CAN BUS - (2 hours)       Category: Avionics

So I got home from work and went out to do a little wiring. Tried making a splice for the CAN BUS for the GTR 200 connector. Messed it up a couple of times. Gave up and came in.
Went back out later and tried again. Finally managed to make the CAN BUS splice.

  Nov 01, 2023     Headphones, connectors, and mics, Oh My! - (6 hours)       Category: Avionics

Made the Gad 27 connector, less the dimmer connections (have an order in with Stein for a new dimmer pot - one of the three had a soldered connector break off). Hooked up wires to the microphone and headphone jacks. I need to wire up the panel PTTs and then I should be able to make the GTR 200 D-sub connector.
Still have to work out the best way for the power wires to go the fuse panels.

  Oct 27, 2023     More Miscellaneous - (4 hours)       Category: Avionics

I'm running low on wire so I have to make another order so I have been measuring the wires that I don't have in order to know what to order - I think that is about done.
After priming and painting, I riveted a terminal board in the forward fuselage for the Keep Alive power junction and the Lighting Bus junction.
After priming and painting, I mounted the two terminal boards below the left seat - one for the wires coming from the control stick grips and going to the boxes up front; and the other one for light wires coming from the left wing.
Also, after priming and painting, I riveted the GD-40 mount to the sub instrument panel, below the GAD 29.
And for the last item, I put the shims under the piano hinge on the left and right side of the firewall (for mounting the cowl), and also under the Skybolt flanges on the bottom of the firewall. I think they are about ready to be riveted in place - then I won't have a reason to not mount the firewall in place.

  Oct 25, 2023     Mostly Miscellaneous Switches - (4 hours) Category: Avionics

Connecting some switches like the alternator field switches and battery contactor. Put in a Low Voltage light that attaches to the main alternator regulator.
Fabricated shims to go under the piano hinges used to mount the cowling, and also for the Skybolt flanges on the bottom of the cowl.
Primed and painted the shims and the various supports that I have made to hold terminal bases under the floor pan (for the stick grip switches and wing lights) and the one in the forward fuselage for the Keep Alive Power and for the Lighting Bus. I am having both of those meet in the front fuselage and then having all of the wires from the various boxes meet there too - such as for the lighting bus, wires come from the GDU 460s, the GTR 200, the GNX375, and the GMC 507.

  Oct 23, 2023     More Connectors - (4 hours)       Category: Avionics

Worked on the J243 connector and got all of the systems connected except for the shunts from the alternators. I don't have the 4 conductor 20AWG wire for that so I did all of them except for those two - when I make another Stein order, I will take care of that. I also did a continuity check on everything that was installed.
Then I did the J241 connector - the one with power, ground, the RX-232 in and out, and the CAN BUS.
When I do the Stein order, I am going to get another terminal board - I will use that for the GAD 27 Keep-Alive power and for the Lighting Bus.

  Oct 18, 2023     Connector J244 - (2 hours)       Category: Avionics

Started working on this connector for the GEA 24. It has the position inputs (aileron trim, pitch trim and flap position), fuel quantity, voltage and the discrete inputs - stall, alt air door open, Easy Glide, and CO detector input. I managed to get all of the discrete hooked up but didn't get started on any of the shielded wire inputs. Of course, I did have only a short time - having to work and all.

  Oct 17, 2023     Connectors - (6 hours)       Category: Avionics

So more working on connectors today.
Did the GMC 507 Autopilot connector. To do that, I had to connect the TO/GA switch. I soldered the connectors for the GMC 507 and the GNX 375 Navigation Unit. Then I spent a lot of time making the splices for the CAN BUS - more than I should have had to but there is that learning curve thing. Finally got the connector done.
Next connector was the connector for the G5 Standby Attitude Indicator. The first thing about it was the Lightning Protection Module - I had to figure out how that was connected but a little research and reading solved that issue. Got it all hooked up and have a three wire going to the GDU 460 for future hook-up.
Lastly, I ran the 18AWG shielded wires for the fuel quantity indicators. I'm not sure how those hook up and I think I need to drill a hole in the fuselage side. I will be calling tech support at Vans to figure this one out.

  Oct 11, 2023     GAD 27 Connector - (3 hours)       Category: Avionics

Looked at the wiring diagram and realized that I could easily make the J272 connector for the GAD 27 so I wired that one up. It just had the connection for Pitch and Roll power, pitch and roll ground, and Pitch and Roll trim outputs. Nothing special and just a few wires so I wired that one up and have a small feeling of accomplishment

  Oct 08, 2023     Sensors - (3 hours)       Category: Avionics

Got the Oil Pressure, Fuel Pressure, and Manifold Pressure sensors out of their boxes and mounted them on the manifold on the firewall. Then I ran wires from the sensors to the GEA 24 area. Next, I made connectors using .110 wide Fast-ons and .020 sheetmetal. I connected all of those sensors and heat shrunk the connections. All of the wires were too long so a little wastage there. I made connectors for the Oil Temp sensor and ran that wire to the GEA 24 area too. I made sure to test the continuity of all of these connections and label them at the GEA 24 side to make constructing the D-Sub connector easier - and I should be doing that real soon.
I checked the box of miscellaneous engine stuff and found field wire connector were already made and hooked to wire so I took those out and put them in the appropriate area.

  Oct 07, 2023     Control Stick Grips - (4 hours)       Category: Avionics

Just got a package from Stein that had terminals and some wire. I had been waiting for the terminals so I could finish connecting the control grips to the black boxes. The wires come from the stick grips to a terminal block under the pilot seat. From there, three of them are singled up (Frequency Flip/Flop, Ident, and Autopilot Disconnect/CWS) then two of those (Flip/Flop and Ident) and all of the rest of the wires (Trim, Grounds, and PTTs) go forward. The A/P Disconnect just goes to the Pitch and Roll Servos. Now that all of those are connected, I was able to remove the platform that the terminal blocks are sitting on so it can be primed and painted.
Another thing that was waiting on the package from Stein was the CHT/EGT connector for the GEA 24. I had taken the CHT wire measured it out and cut according to the measurement - I didn't measure twice and cut once. So the last wire was too short. With the wire from Stein, I was able to make the last connection and complete the J242 connector for the GEA 24.
Another thing I did was to lift the fuselage into the air so I could drill out the rivets holding on the Skybolt flanges on the bottom of the fuselage/cowling interface. I have to put a shim under the flanges and then re-rivet them back into place. While it was up, I drilled the holes needed for the flap rods.
I have a number of things to prime and paint, including those shims. Once they are painted, I will be able to rivet the piano hinges to the firewall sides, the Skybolt flanges back on the bottom, the GD-40 mount on the sub-instrument panel, and the supports for the terminal blocks mounted under the cockpit floor (one for the left wing connections and one for the control grip wires).

  Oct 02, 2023     Wiring it up - (5 hours)       Category: Avionics

Getting going on wiring this project up. Had to pull a wire out because it didn't have enough length from the conduit it was in. I put it in a different conduit going under the floor and now it is long enough.
I put the Manifold Pressure sensor, the Oil Pressure sensor, and the Fuel Pressure sensor on the firewall manifold. Then I ran the wires to them but with some extra since I don't know exactly how the routing will be once I install the engine mount.
I made the D-Sub connector for the GEA 24 that has the CHT and EGT sensors. Almost. That is, I connected all of the CHT and EGT wires to the D-Sub connector except for one wire. I mis-measured the wire and the last one was too short so I will have to get more wire to finish that. But once I get that wire, I can finish that connector and run the wires out to the engine compartment.
I looked at how to mount the ELT and haven't come to any real decisions yet.
The other thing I did was to connect the ground wires for the control stick grip switches. The CA side was easy - straight to ground. The FO side goes through a switch, the Copilot Enable switch. That way, I can flick the switch and none of the functions of the co-pilot control grip work - great if you have kids or non-flyers in the right seat.
Easing into making the connectors for the black boxes.

  Jul 06, 2023     Avionics Doublers - (4 hours)       Category: Avionics

Located the avionics boxes and built doublers for the GEA 24, the GAD 29, and the GAD 27. Waiting for some nut plates to arrive.

  Feb 12, 2023     Shopping - (2 hours) Category: Avionics

Spent awhile shopping at Steinair for installation kits for the Garmin system. Measured wings and fuselage to figure out how much wire is needed.

  Feb 11, 2023     Woodboxes - (5 hours) Category: Avionics

Cut "black boxes" from wood to the dimensions of the Garmin avionics that are planned. Using these pieces to determine the best placement on the sub panel behind the instrument panel.

  Jan 23, 2023     Wiring Diagram - (5 hours)       Category: Avionics

Worked on overall wiring diagram. Took each of the component diagrams and put them on a single sheet of paper then printed out each of those. I then taped each of those sheets together - 6 across and two high. Then I drew connections between each of them corresponding to the pin-out diagrams. Had to do it a couple of times before I came up with a final draft. Once I had the final draft, I took it to Staples and had them print it out on a single sheet of paper. I then took a foam board with adhesive backing and glued the paper on the foam board.

  Jan 17, 2023     Stein Visit - (2 hours) Category: Avionics

Went to Stein in Faribault, MN. Took my diagrams of each component on a page of paper with the pin-callouts. Also showed him the overall wire diagram. He said it was too disjointed - said it was best if it can be one diagram. He showed me what he meant - he brought out a 6' x 8' wire diagram with all of the components and the wiring between them.

  Sep 05, 2022     Ignition Key - (3 hours)       Category: Avionics

Fabricated a swing-down holder for the ignition key - it really is just an "Enable" key since I am using a START button. This enable key will enable power to get to the starter relay.
Also wired up the Main Distribution Fuse Block to the copper bus bar on the circuit breakers.

  Feb 17, 2022     Stein Air - (1 hour) Category: Avionics

Talked to Stein at Stein Air and put in an order for avionics connector kits along with wire and numerous other items.
-Servos and the. System LRU kit are on back order
-Panel cutting/engraving/setup and painting was about $2500 but they are backed up for months
-After I have the wiring diagrams figured out, they will give it a cursory look for free. In-depth look requires hours and will be charged.
-Conversely, they can create a wiring diagram with all of the components that I have selected for about $1000. Everything mapped out on a 6' page.
-Recommended against the FlyEFII system. Ideal for someone who is conversant with electronics and who likes tinkering with race engines. Not ideal as a plug and play system. Not to mention the single-point failure issue - relying on the aircraft electrical system and not self-contained.
-Decided to go with EMag electronic ignition system's PMags, self-contained like a regular magneto with it's own power source.
-By ordering all of the systems, I got a few % off. Ordered the connector kits.
-Will order the actual black boxes and panel faces as it gets closer to the actual flight date.