Firewall Forward

EAA Tech Counselor Review

Terry Moushon, a new EAA Tech Counselor spent several hours inspecting & discussing my build status and plans.   Terry built a Vans RV10 (4 seater), and first flew May 2016.  He's the builder I visited in 2013 & 2014 prior to my decision to proceed with building, and he's been very helpful.   He shared numerous insights into his recent experiences -both building and flying/maintaining.   He also recommended several enhancements or features I can do to improve durability and maintainability.   I received very positive, complimentary notes from his review ( this is #4, with Sam Sisk doing first three reviews during 2016)   Terry's a terrific builder and makes an excellent Tech Counselor.  Thanks Terry !

Avionics

Auto Pilot Servo  ( 3 hrs )

Installed Garmin Auto Pilot Servo GSA 28 for roll in right Wing per Sect 56-05, Steps 1-12.  Tight & awkward  access took lots of time and many different tools, but got 'er done.  Tried to assemble Garmin Magnetometer GMU22 to Van's Mounting Kit, but Stein Air forgot to include the Mount Ring from the connector kit.  They mailed it today.

discovered Stein Air forgot to include Mount Ring
for Magnetometer (its now in the mail)

Firewall Forward Kit

Sensors installed on Firewall ( 1 hr )

Installed Garmin MAP Sensor (Step 5 at Sect 43-03) on Firewall,  and Oil Press and Fuel Press Sensors on Sender Mount (Step 5 at Sect 43-04).   I rec'd these as part of shipment from Stein Air of all components not mounted directly to Panel.

Manifold Air Pressure sensor

Oil Pressure sensor on left,  Fuel Pressure sensor on right

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.