Firewall Forward Kit - Propeller

Propeller Mounting and Alternator ( 3 hrs )

Torqued Propeller Mounting studs to 65 ft-lbs per Table 3-1 and Fig 3-2 ( Step 1 = 40 ft-lbs, Step 2 = 65 ft-lbs) in Hartzell Prop Owners Manual #115N.   Safety wired and applied Torq Seal.  Adjusted alternator belt tension per Maint Procedures Sect 5, page 5-8 in Lycoming Op Reference Manual for IO-390 series.   Set by slip torque method to 145 in-lbs (midway between 132 to 156 in-lbs for New belts. Note: Used belts set to 84-108 in-lbs).  Safety wired lock bolt.

Works well, but wow is this tool expensive.

 

 

added torq seal

alternator belt tension set, so torqued and
safety wired lock bolt

Firewall Forward Kit - Propeller

Propeller mounted ( 4 hrs )

Safety wired alternator attach bolt per Sect 51-06 (waiting until after Prop installed to tighten Alt belt - so I have a lever to resist turning engine while using the torque/belt slippage process).    Re-opened Propeller box (rec'd late 2017 since ordered same time as Engine to get discount Vans offered) and moved to floor with wife's help.  Mounted Spinner Plate to constant speed hub - torqued to 21 ft-lbs per Table 3-1 in Hartzell Owner's Manual.  VAF has good recommendations from builders on how to remove plug in crankshaft (oil passage to CS prop)  - and it came out easily with slide hammer.  Used engine hoist w/ straps to lift/position Prop to install per Sect 44-02.  Tightened 6 places, but didn't torque/safety wire ...yet.   Reference data on Prop:  Model No. HC-C2YR-1BFP/F7497     Assembly Serial No. NS3530B    Blade 1 L82636,  Blade 2 L82641   ( Low pitch 13.6  High pitch 35.0)

Alternator  safety wired...
Belt tension not yet set for other bolt

"Thar she be..."

Serial No. NS3530B.   (Plate says A-2424 Rev 0 )

Prepping to mount Spinner Plate

Hartzell PC10 TC P920   HC-C2YR-1BFP

        Sticker confirms documentation:
Blade 1 Serial # L82636, &  Blade 2 Serial # L82641

B-2428-1  Rev AS   SN171765.

Confirmed O-Ring in place as mounting Spinner Plate

Torqued Hub Clamp Bolts to 21 Ft-lbs per Hartzell manual

Followed VAF recommendations to remove
plug  in front of crankshaft.   Came out easily...
with couple ounces oil spilling out.

Nancy helped secure Propeller. 
It's a lot easier with two people!

Yay!   It fit....

Tah Dah !   
Looks big since close to camera...

Firewall Forward Kit - Propeller

Propeller and Spinner  ( 3 hrs )

Finished cutting out center of Spinner Plate.  Deburred, cleaned and primed with Napa 7220 self-etching primer.  Riveted Doubler to Plate per Sect 44-02.  Deburred and primed S-603 Front Spinner Bulkhead.

nearly done cutting out center of Plate

mostly done deburring....ready to prime, then rivet

Riveted.   Decided to leave doubler "as-is" with pure alum
coating for corrosion protection

Firewall Forward Kit - Propeller

Canopy Harness and Propeller & Spinner ( 3 hrs )

Added Wht/Blk wire with Molex male pin to Canopy Harness for Pin #7 position to connect to 3rd wire for Red LED and White LED strips.   Added silicone at two places where canopy latch warning wires enter and exit canopy frame on LH side.   Started Sect 44 Spinner & Propeller w/ Steps 1 & 2 at 44-02: Spinner Plate and Doubler Ring.   Good to get back to working on aluminum vs wires.

Bolts hold doubler in position to match drill #30 holes. 
Marked cut line on Spinner Plate

drilled and cleco'd  

Lots of deburring, then cut center out of Spinner Plate.  

Avionics

Canopy Harness ( 2 hrs )

Crimped connections w/ butt splice ( ES320559) for both defrost fans for Gnd and Pwr wires (includes Gnd from micro-switch for canopy warning).   Routed/protected wiring with spiral wrap.  Remaining wires will connect to separate Red LED strip and to White LED strip once received ( Josh at Stein Air shipping free replacement of combined Red-White LED strip-- recently determined I would need an extra switch due to config of G3x and GAD27 if I use the combined LED )

updated pic of harness wiring after lacing
wire bundle 

butt splices for defrost fan,  partially spiral wrapped

almost done  ...now realize I need 3rd wire from LEDs back to
Pin 7 in connector.   DOH !   So I get to redo...

Avionics

Canopy Harness continued ( 1 hr )

Update 5/29/19: needed to switch Fuel Pump On to Discrete #2, so Discrete #3 could be aligned with Canopy Warning.  #3 is locked in by Vans program for Canopy Warning uploaded into G3X.  So I switched Purple/Grn wire and Purple/Blu wire in connector J244 at GEA24.  This aligns Purple/Grn to Pin 41 and Discrete #2.   And Pin 42 = Discrete #3 (now #2) for Purple/Blu wire.


Per Sect 61-03 and Van's W00125 schematic for canopy wiring, crimped on 6 Molex pins into ES00012 connector.   Snapped into F01477-L.   Stein provided heat shrink labels.
reference:
Pin 12   Discrete 2   [now Discrete 3 ]           (Purp/Blu)
Pin 11   Gnd                        (Blk)  from forest of tabs on firewall
Pin 10   Defrost Pwr           (Red)
Pin  9    Cabin Lights Pwr  (Red)
Pin  8    PWM Light 2        (Wht/Blk)
Pin   7   PWM Light 1        (Wht/Blk)
...and  PWM Light 3, DC Light 1, 2 & 3 unused...

Partially done inserting pins

Connector in place, pending  wire protection.
PWM 3, DC Light 1, 2 & 3 unused,
(ends covered with heat shrink labels)

extra schematic Stein Air's  Josh Swensen provided....shows how
2 LED strips should be connected

Avionics

Canopy Harness installation ( 4 hrs )

Added cushion clamp ( size -7) to retain extra cable at LH sub-panel forward of G3X Touch 460 panel, etc.  My wife Nancy helped re-mount canopy so I could start Canopy Harness installation.  Routed 40" of safety wire through LH side of Canopy per step 5 in Sect 61-03.  Drilled holes for Garmin GA 26C GPS antenna in upper surface (ie dash).  Since BNC connector pre-connected by Garmin to antenna, needed 3/4" hole to pass (used uni-bit).  Mounted w 2 supplied screws.  Tah-dah!  Prepped 2 defrost fan's black & red wires per Steps 1 & 2, Sect 61-02.  Routed W2128 (Wht/Brn) and W2129 (Blk) wire through canopy frame pulling pre-positioned safety wire out of aft oval hole per Sect 61-03, Steps 1-4.  Protected these wires along canopy shelf via clear spiral wrap retained with cable ties.

cushion (adel) clamp securing extra harness. 

mounted GA 26C GPS antenna per Sect 61. 
(pre-attached BNC to wire req'd 3/4" hole to pass)

safety wire routed from front to aft
opening in LH canopy

wires pulled through, crimped connectors, & attached to micro
switch. (warns canopy not latched if RPM above 1700 RPM )
[ note: silicone sealant in oval opening yet to be added ] 

wires routed to center, gathered with LH defrost fan.

translucent spiral wrap added,
secured w/ cable ties