Van's RV-9A in Aurora

The Big Picture

The Big Picture
Flying! 8/28/2011

Thursday, December 30, 2010

6 hrs
Finish flaps wiring.
Finish FWF sensors.
Finish aux fuel pump circuit.
Start installing trim circuits.
Spending some time working on the schematics. Need to catch up to where I am in actual construction.

Wednesday, December 29, 2010

About 6 hrs
More wiring.
Received a Dynon care package yesterday, so started with the tach pickups. This involved tapping into the magneto lines with 30K ohm resistors. The resistors have very thin leads, so it takes a while to build up a connector that can stand the abuse of life behind the panel.

Wired in the pitot heat circuit to the switch, along with the LED indicator.
And finally, wired up all the LED with grounding, and pigtails for the controlling signal. Included in this was the EFIS warning LED. Only the fuel pump still left to wire to complete the LEDs.

Also rewired the transponder GPS serial in line. This has a resistor inline, and I wasn't happy with just the resistor exiting the connector. So wired it up so that the resistor is doubled back against the wire, with lots of heat shrink to add mechanical sturdiness.

And yet more wires!

Tuesday, December 28, 2010

4 hrs
Been bad about posting, but have been working on the project. Dad and Patty have been in town for Christmas, and Dad has been over to help out for short periods during the holidays.
It's been all about the instrument panel. Among the accomplishments was getting the main harnesses for both Skyviews wired in, at least well enough to power up the two displays. John installed nutplates on the radio stack braces, so the stack can be screwed to the panel now. I guess I've missed writing up about 8 hrs of work over the past few days.

One Skyview is alive!

Today, got the SL-40 install mostly done, including making the coax connector, and got the radio stack with the Stein harness into the panel. Decided to trim the subpanel a bit more to clear the audio panel connectors. As a result I have a new favorite tool. I bought a hand nibbler from Avery. Built the airframe without it, but it sure is handy. While the noodles were cooking for dinner, I was able to mask in newspaper, nibble out the cutouts, file, sand, scotchbrite, and clean up, just as the noodles were done. Any other cutting tool would have required that much time just to set up and to cleanup the mess.

The Dynon transponder requires a TNC connector. Those things are ridiculously expensive. And I don't have one.

Over the past few days I've had to do a LOT of research on various items. I've had the attitude that this wiring and panel task would be a piece of cake. My professional experience gives me a big leg up on this kind of work. But I have to admit there are a lot of items that aren't immediately obvious, even after all the prep work has been done. I feel for the guys who aren't comfortable with this stuff.

Thursday, December 23, 2010

2.3 hrs
Reinstall gascolator and aft fuel line. Need to order hoses to complete the fuel system.
Label manifold pressure and carb heat electrical lines and start installing connectors. This after finalizing all 37 pin signals, including allowances for cabin temp, trim, heated pitot status and EFIS warning light.

Wednesday, December 22, 2010

2 hrs
Still not getting much time for the project.
Shrink wrap fuel level sender, manifold pressure, and fuel flow leads.
Route ADAHRS network cable to right side Skyview.
Spent a couple of hours over the past days with minor stuff. Waiting for Spruce and Stein orders to make more wiring progress, and of course there are xmas items consuming most of the time.

Did finally identify the stray power/ground pins on the EMS 37 pin connector, and installed 1/4" and 1/8" ID tubes plus a reducer for the manifold pressure sensor.

The Spruce order did come in, so after chores today, should be able to make some progress on the project.

Sunday, December 19, 2010

2.5 hrs
Make bracket for Fuel Flow sensor.

And more wires get added to the panel.

Thursday, December 16, 2010

2.5 hrs
More wiring. Continued sorting and running wires for the Dynon EMS pod.
Route fuel level sensors, carb heat, manifold pressure lines. Started attaching terminals for carb heat. Need a bunch of 1/8" heat shrink to make nice bundles for the fuel level sensors, and some of the wire bundles going through the firewall.
Placed a Stein order today to pick up some of these items. Also need to place a AC Spruce order.

Wednesday, December 15, 2010

3 hrs
Finish OV/LV monitor wiring.
Make 26g Fusible links for ammeter input lines.
Start setting up EMS 37 pin connector wiring.

Didn't say anything about it the day of this post, but an early present came from the Pacific Northwest. The seats and 5-point Hooker Harness sets from Classic Aero came today. They look great, and I'm happy I spent the extra bucks to upgrade the harness release - they are top quality.

The flash makes the red look brighter than it is. It's really a deep bergundy, in fact, that's the name of the fabric. These are the ultraleather seats in Raven and Bergundy. The carpets are much lighter, a grey color. It's an odd combination, but the seats will make the cabin very dark, and I wanted to be able to find things that get dropped on the floor.

Tuesday, December 14, 2010

1.5 hrs
Wire starter switch power feed.
Start wiring overvolt/undervolt monitor and LED.

Monday, December 13, 2010

2 hrs
Continued with wiring.
Connect master switch. Main buss is now switched.
Connect oil pressure/master-on sender and LED. For this I use the Van's Hobbs oil pressure sender. 12V is hooked up to common, and an led to the NC connector. When there's no oil pressure, the red LED comes on. It has the extra duty to be on when the master switch is on, reminding me (hopefully) to turn it off at shutdown time. No need for a push to test, just turn on the master.

Sunday, December 12, 2010

8 hrs
Started wiring in earnest. Electrical system design based on AeroElectric Z-11.
Start right side EGT and CHT connections. Need more connectors from Dynon.
Wire ELT panel connector. Tested the ELT for the first time. Broadcasts on 121.5, at least, and batteries expire in 2014, date of manufacture 2009.
Route and trim static and pitot lines to TruTrak AP.
Mag P leads.
Master contactor control lead
Starter contactor control lead

Saturday, December 11, 2010

5 hrs
Finished up a few FWF tasks that had stacked up waiting for parts.
Torque engine mount/firewall bolts. Install cotter pins.
Install oil breather tube.
Install fuel overflow line for overboard venting.
Install 90 degree T fitting for fuel pressure hose installation, install fuel pressure hose hand tight.
Start installing CHT and EGT spade connectors. Burned three of the connectors installing them wrong in the crimpers. They were in backwards, and the resulting crimps failed the wire security test (pull at about 10 lbs to make sure they hold).

Wednesday, December 8, 2010

For Tuesday, Dec 7
1.4 hrs, 14 rivets
Install nutplates for arinc and transponder. Start routing wires for engine instrumentation.

The gold colored box is the Dynon Mode-S transponder.

Monday, December 6, 2010

1.7 hrs
Start mounting Airinc and transponder modules.

Sunday, December 5, 2010

4.4 hrs
Finish cutting holes in panel for all switches, leds, autopilot.
Deburr panel.
Drill holes for headsets and music input in side panels. Meant to include 12V receptacle on passenger side, need to see how I can recover from the error.

Saturday, December 4, 2010

7 hrs, 4 rivets
Finished the radio stack braces. Rivet tabs for attachment to subpanel.

Cut panel for radios.
Cut panel for ELT switch.
Drill panel for Skyviews, drill for nutplates.
Drill #40 center locations for all switches and air vent cutouts.

Received the order from Van's, almost done buying parts from them for the build phase of this plane, maybe one more order.

Put in .5 yesterday on the radio stack frame.

Thursday, December 2, 2010

1.7 hrs
Drill radio stack braces.
Make and drill panel angles and SL-40 shims. Almost back to where I was on the radio stack from the first iteration. This one is working out much better so far.

Wednesday, December 1, 2010

1.1 hrs
Continue radio stack design.
Start cutting side braces.