Drip pans / drill mount holes

Worked on putting together the carburetor drip pans. This involved riveting some doublers then applying fuel sealant to fill in holes and also to attach a doubler.

I then worked on drilling the holes in nose gear assembly. I was able to finish drilling the left hole as per plans, but due to time will need to continue next time.

Time: 2 hrs.

Drip Pans

Left hole Drilled

Engine installation started.

Engine was revealed today. I unblocked it and used the tractor forks to place the pallet on a table so it is at a better level to work on. The first thing to do was to re-position the water inlet.  A retaining screw was removed at the rear of the ignition module and the wiring harness was separated. A cushion clamp was removed and a bushing placed as per plans.  The trigger coil clearance was checked and was good. I had to run to the store to get some gauges to check clearance. It called for 0.012 - 0.016.  The starter lug was removed as per plans.The lower coolant hose were then remove in preparation for attaching the engine mount.  I then proceed placing the engine mount. This took a little time as it was a very tight fit (plans said it would be). I had to be very careful not to damage the coolant tubes.  Bolt were places and torqued to 30 Ft lbs (360 in lbs) as per the Rotax illustrated parts catalog.  RTV sealant was then places on the VA-216 line as per plans.

Time: 4.25

Engine Revealed

Water inlet repositioned

Retaining screw

Wiring harness disconnected

Bushings placed under cushion clamp

Trigger coil clearance good.

Starter lug removed

Hose disconnected

Mount attached to engine

RTV on VA-216

Firewall FWD Harness 2

Found the starter relay in the Rotax engine box. I installed it and also the Fuel pressure sensor. Wiring was then completed that attached to the manifold pressure sensor, master relay and starter relay.  The plans called for running the wires through a cushion clamp on the engine mount standoff, but I could not see anywhere in the plans were these cushion clamps were called out so I installed some that best fit.

Next session will call for breaking into that rotax box and starting to disassemble some of the engine parts in preparations for mounting the engine.

Time: 2.25 hrs.

Starter relay

Fuel Pressure Sensor

Wiring to manifold pressure sensor

Wiring to master relay

Firewall FWD wiring

Firewall FWD wiring

Firewall FWD Harness

I installed the right panel and mapbox, attaching the GPS 20A to the top of the mapbox.

I then started the Firewall forward wiring harness. This required a few wires to be put through the holes in the bottom of the panel. A little tricky with the transponder installed, but doable. Wires were then placed through grommet in firewall. The pitot tube pieces were then joined with a short piece of tubing and also placed through the firewall.

Battery, master relay, and manifold pressure sensor were then installed. The plans called for installed a starter relay, but I could not locate it. Later in doing some reading on vansairforce it was stated that it is with the engine. I will have to look for it next time.

Time: 2.5 hrs

Mapbox installed

Right panel installed

Battery

Master relay, and Manifold pressure sensor

Battery wire

Firewall FWD harness

Wires nicely tie wrapped

Avionics Cont.

Big accomplishments today. Started with installing the center panel and Power & Switch module.  The potentiometer was then installed. The left panel and Ignition & Start module was then installed.  Then followed the GMC 307, COM radio, and Autopilot disconnect switch.  The panel is starting to look good.

The GEA 24 along with the wiring harnesses were installed along with the transponder and GPS 20A (that will attach to top of mapbox).  There were a couple wires that were ran to the pitch servo and had to replace a couple wire in the connector. The G3X was tried in. I will wait until later to permenantly install. A wire in the EFIS wiring had to be spliced so that was accomplished as per plans.

I then went back through the plans and decided to do some of the misc. section. The baggage floor, and seat floors were installed along with the crotch strap for the seat belts. It is almost time to be out of the cockpit and onto the firewall forward.

Time: 8.5 hrs

Center panel and Power & Switch

Potentiometer

Left panel and Ignition & Start module installed

GMC 307 installed

Com radio installed

Autopilot disconnect

GEA 24

Pitch servo wiring

Pitch servo

G3X tried in place

Red/White wire to be spliced

Wire spliced

Transponder, GPS 20 A wired

Panel wiring

Panel wiring

Baggage floor installed

Floor installed

ELT, Panel Paint, wiring

My center panel arrived today so first thing was  to mark and cut the location for the GMC 307 autopilot. Holes were countersunk as per plans. The map box was then riveted to the right panel. The panels were then primed and painted with Rustoleum Hammered Black.

Then work continued with the ELT. The instructions required soldering of some wires to the connector for the ELT. Not being experience in this I had to revert to youtube for a bit of instruction. After a little trial and error I was successful in getting 4 wires soldered to the small pins in the connector. One wire was placed for testing in future if required. I also attached a ground wire and bolted it to the ELT bracket. The ELT and antenna was then installed.

Having read through some of the following sections I decided now would be a good time to place nutplates for the voltage regulator. There is the option of placing bolts and nuts or nutplates. The nutplates will allow for easier replacement in the future if needed.

I then finished up with the wiring in the tailcone. The following were completed: Aft pitot line, Static line, OAT, CPC connector magnetometer, D-sub connection, connections to ADAHRS.


Time: 5.25 hrs

Cutout for GMC307 Autopilot controller

Panels ready for paint

ELT antenna bracket

ELT connector wiring diagram

2 wires soldered

Wires soldered to connector

Wires soldered to connector

Wires soldered to connector

RTV sealant placed

Connector done

ELT mounted

Ground wire

Nutplates for Voltage regulator

Pitot static line attached to ADAHRS

Connection for magnetometer

Wiring in tailcone

Wiring in tailcone

Wiring to ADAHRS and Roll Servo