Engine and Avionics

Final Mounted Snorkel, LED interior lighting, and STILL can't find Fuel System Leak ! ( 4 hrs )

Removed Snorkel (air intake plenum) from fuel servo so I could remove tape at throttle interface (added more than year ago to keep engine "sealed").  Tightened four 1/4" bolts, then safety wired.  Ref 47-17 and 47-22, Step 15.  Also Configured Lighting in G3X for Red and White LED strips on canopy.  In Config mode, selected Cockpit Lighting, then chose PWM Lighting Bus 1, and Input 2 for White LED.  Set 0% at 0.0v, and 100% at 12V.  Same for Red LED, except Bus 2, Input 1.  (After pics taken, I revised setting 30% at 7v for each, so lower portion is easier to modulate...ie non-linear.  Pic shows original linear input vs output plot).    Still haven't found tiny leak in fuel system (approx 15 psi in 30 min) ...after another 3 hrs with multiple doses of soap bubbles .  Connected test equip at input to fuel filter, and got same leak rate - proving fuel valve is NOT source of leak.  Re-checked thoroughly every joint from Wing connection to fuel servo...with lots of soap bubbles.  NO joy!  Totally encapsulated w/ soap bubbles the mechanical fuel pump, electric fuel pump, and  Red Cube fuel transducer - trying to detect poor gasket, crack, etc. No joy.    So I loosened a connection on test equip, and was surprised although covered in soap bubbles - it didn't "indicate" a leak until I opened a much higher rate of 1 psi drop per 1-2 seconds !  Vans product support wasn't much help today...indicating soap bubbles should work. (Sterling did suggest dunking entire fuselage in my swimming pool, and look for bubbles ...ha !)  Another builder (Bill Lane, who's been very helpful) suggested I purchase gas leak detection "blue" fluid (available in hardware stores).  It may work better.   One advertises capable of magnifying micro-gas leaks as small as 0.65 oz/year into visible foam "cocoons".  Wow!  IF this doesn't work, I'll have to wait until Wings attached, fuel tanks connected - so I can test for leaks with aviation fuel.  VAF has tips to use white paper towels at connections, to show the blue stains from dye in avgas.

blue tape over drainage hole in plenum...with
hanging portion to insure removal prior 1st start.

 

 Red LED for night flights ....dimmed to medium intensity

White LED...good for general purpose in hangar, etc 
Red and White dimmer switches are in upper LH corner of panel

with Canopy raised, serves as overall interior lighting. 
This is at less than 1/2 intensity

Spent hours covering joints in soap bubbles,
inspecting w/ lights and mirrors.  No joy...yet.

Engine and Avionics

EGT sensors connected ( 2 hrs )

Per Sect 48-07,  Steps 1-3 completed wiring connections to 4 EGT sensors.  Added safety wire to hose clamps per Alcon Tempest instructions per their recommendation.

front Right EGT sensor connected

back Right EGT sensor prior  pulling
protection sleeve over connections

Overall pic of Right side.  ( note: Spark plug wires not
connected for LH magneto...still have desiccant plugs installed)

Left side.  ( The automotive plugs are installed on bottom
 on this side for PMAG electronic ignition)

Engine

EGT sensors (and more Fuel System leaking ? )  ( 3 hrs )

Back to trying to find leak in Fuel System !  At first, thought yesterdays leak discovered and repaired completely solved Fuel System "leak"...but after 1 hr, the 30 psi air pressure slowly dropped.  So today repeated - and now won't hold pressure for more than couple minutes.  Redoubled efforts with lots more soapy suds...thoroughly covering every possible joint or leak path -- No joy.  To confirm not test equipment, I positioned Fuel Valve to OFF...and it held pressure.  So considering if internal leak in valve from LH to RH side. But tested for air transfer to RH side (tube added to fuselage fitting, ending under water...no bubbles!) -- again No joy.   So tomorrow I'll try to isolate (remove hose to engine fuel pump, cap and test that section)...with more soap bubbles.   Meanwhile installed all 4 EGT sensors Type K thermocouple (from Garmin G3X sensor kit, Alcor Tempest #86255, which is Garmin #494-70001-00).  Reamed holes (pleased already drilled in exhaust tubes) w/ #30 reamer since press fit.  Need to finish wiring connectors, add safety wire.

re-checking for leaks in fuel system...

getting frustrated....total immersion seeking possible leak
in "red cube" fuel transducer itself, as well as connections

EGT sensor installed, still need to connect wiring.
Sensor is press fit into #30 hole...so tight and leak free

Left side  (not yet connected to brown thermocouple wires

Right side

Added pic of sensor for reference.

Engine

Exhaust and Fuel System ( 2 hrs )

Completed Heating System w/ last DG-12 adel clamp on engine mount tube, attaching DG-32 holding 2" SCAT hose to LH Vent.  Finally...yay!  Repeated 30 psi air pressure leak test of LH Fuel System (I ordered/received AN 6 sized cap for RH side to insure not leaking during test).  Using soap suds, discovered tiny leak between Fuel Pump and Fuel Filter on pipe threads.  Disassembled, re-applied thread sealant - and NO leaks for 1 hr.

2" SCAT hose routed to LH Vent.  Clamps
position hose clear of  potential rub points

Discovered tiny air leak at pipe threads during pressure
 test (center of pic).  Bubble grew over couple minutes. 
Removed inline filter from Fuel Pump, re-applied
 pipe thread...no leak.

Engine

Exhaust ( 3 hrs )

Installed lock washers under Exhaust flange nuts, & torqued to 190 in-lbs per 48-03, Step 7 & 8.  Needed special 1/4" drive, 1/2" flex socket -- only way to fit onto nuts since exhaust pipe clearance is minimal (VAF has posts noting other builders found same solution.  Surprised Vans instructions don't call out this tool requirement)  Added Sniffle Line Assly per 49-18, Steps 1-6.  Required adding Bottom Cowl Support Bracket plus couple more adel clamps.

1/4" drive, 1/2" flex socket barely fits...
to tighten exhaust flange nuts

Added heat shields in 3 locations

bottom view of heater 2" SCAT hose behind
engine toward LH vent

Sniffle Line Assembly installed.  Yellow cap has blue tape to insure I remove prior to 1st  engine start 

Engine

Heat Muffs, etc ( 3 hrs )

Completed Step 6, Sect 48-05 - 2" Vent Tee.  Limited space to 1st install two Adel clamps to engine mount tubes, then very large Adel Clamps around 2" Vent.  Used safety wire to hold clamps in position.  Overall took a lot of time to get positioned correctly - and lots of various tools!   Glad that's done !

Using tool to hold clamp closed so I can
hold closed w/ safety wire

In the end, I used many tools to get  'er done.

close up showing clamps secured

And overall shot showing 2" SCAT hose routing 

Engine

Heat Muffs ( 3 hrs )

Installed Heat Muff assemblies per Sect 48-04, Steps 1-6.  Added couple of the SCAT 2" hoses per 48-05.

1 of 2 heat muffs added.

Both heat muffs added, & interconnecting SCAT hose installed

hose connected for air intake