Firewall Forward Kit

Relocating Throttle/Prop/Mixture Cable Controls (3 hrs )

Trial fit the T/P/M cable template (repositions these cables at bottom of Panel, instead of just below on bracket to provide greater knee room).  Stein Air's Nick Millard has done great job creating this template using 4 mounting screw locations as key reference point.  I used to mark "half-moon" portions of lower crossmember to remove.   Cables installed perfectly, only requiring removal of bracket mid-way back from Panel.   Cable will be anchored to other existing shelf, and use original clamps on LH and RH side, and snap bushing in center.   Designed a doubler to provide uniform contact surface for lockwashers/nuts (just above the crossmember).  Nancy and I both tried them out with successful flights !

prior to removing "half moons" from crossmember.

1 nutplate in center was removed.  Stein Air uses a single Panel,
instead of 3 pieces (center, LH & RH)...so plenty of strength
 even with cutouts.

without doubler above crossmember...

new position about 1.5 inches higher.  They are slightly closer
 (to fit between internal vertical walls).  The Alt Air knob
 is now above, vs below others.    No bracket below Panel

fits me (6 ' 4" tall).   Good hand clearance

fits Nancy  (5' 10" tall)

outline for doubler behind Panel

Firewall Forward Kit

Stein Air non-Panel components (1 hr)

Rec'd large package from Stein Air including all components that aren't directly mounted on Avionics Panel they're building.   Fuselage Common wiring harnesses, several antennas, ELT kit, Auto Pilot servos, Engine Sensors.   Also the test fit template for relocated Throttle, Prop & Mixture control cables.   Lots more to assemble !

I'm replacing bracket below panel w/ direct mounting  to bottom
edge for better knee clearance.   I'll use template to mark clearance
 holes in lower perimeter frame, so actual Panel from
Stein Air will fit perfectly.

Auto Pilot servo

some of the harnesses, etc

ELT

heated Pitot tube.

Finish Kit

Wing Root Fairings ( 4 hrs )

Completed LH & RH Wing Root Fairings per Sect 41-04, Steps 1-14 (except Steps 6-9 requiring Wings installed ).  Completed deburring, then dimpled all holes (for #8 screws, and rivets).  Riveted 18 stiffeners onto Top Fairings using rivet gun with back rivet tool and metal back up plate - really easy.  Marked and bent Lower Fairings to conform to Wing leading edge.  Been awhile since I used these set ups...kinda "fun".

ready to dimple w/ C Frame

back riveting

 

trial fit on RH side Fuselage

Finish Kit

Torq Seal and Wing Fairings ( 2 hrs )

Did some "clean up" of some loose ends in Fuselage:  climbed into Fuse and managed to twist around until I could just barely reach nuts on 6 bolts for Engine Mount to apply torq seal.   Then moved into baggage area to confirm torques and apply torq seal to all fasteners on Elev pushrod bellcrank mount.  Nancy assisted me bending and unbending my 6'4" frame into this tight space.   Next I jumped to Sect 41-04 to Final Drill #17 holes, deburr all edges and holes as prep for LH & RH upper and lower Wing Fairings.

Firewall Forward Kit

Sender Mount, etc ( 3 hrs )

Installed Sender Mount, adding fittings and hoses VA-102 and VA-119 (from Sect 49-11, Fig 2) prior to bolting onto Firewall.  Primed and painted "stainless steel rustoleum color" the Garmin Manifold pressure sensor bracket -- then mounted to Firewall.  Installed WH-P25 AWG Ground Strap, too.   Installed first Adel clamps (hose above, battery cable bottom) using safety wire trick.  Worked, but awkward.  May invest in speciality too for adel clamps since lots to do....

upper LH corner is MAP sensor bracket.

Firewall Forward

Starter Solenoid and Master Relay ( 3 hrs )

Started FF Kit ahead of engine delivery -- so I could mount components to Firewall easily.  Installed Master Relay and Starter Solenoid w/ connected wires per Sect 43-04, Steps 1-4.  Also partially assembled Sender Mount after first priming and painting.

Primed, painted "stainless steel".  Trial fit fittings.

Firewall Forward Kit

Prep for FF Kit / some Pushrods from Finish Kit ( 2 hrs )

Minimal shop time Jan 8 - 10 while working phones and emails with Vans, Stein Air, Aircraft Specialty, and Flightline Interiors.   Vans sending a few items missing/wrong in FF Kit (from 8 pages, only a few).   Working with Steve at Aircraft Specialty for hose upgrades:  planning to replace FF00014 hose with hose specifically made for the single P-Mag on my Lycoming IO-390 for the manifold air pressure sensor (from engine to both sensor and P-Mag).  Very helpful and high quality components (I installed their alum tubing fuel lines, hoses inside fuselage last year).  Working with Nick Millard at Stein Air to finalize Panel design.  They're sending bunch of components now (Auto Pilot Servos, ELT, etc) that I can install while waiting engine delivery.  Over several months (off and on) from concept to final design, Nick has been very helpful getting the Panel just right.  I've also launched Seat and interior development with Abby at Flightline Interiors.  Been a pleasure to get started, leveraging her experience.   Only shop work was building 2 Flap Pushrods per Sect 41-02, Steps 1-5, and 2 Stick to Torq Tube Pushrods per Sect 41-06, step 1.

3rd from bottom hose needs modified to work with P-Mag. 
Planning to replace with hose from Aircraft Specialty.

Latest, maybe final design of VFR panel. Will be black,with white engraved 

labels.  Toggle switches.  Moving T/P/M controls to bottom of panel, 

vs Vans orig design with addition below Panel (improves my knee room !)

Abby at Flightline Interiors had example of
Vinyl seat with fabric insert very similar to
our concept.  Not this logo w/ "pink" color...