Avionics

Circuit Breaker re-visited and Canopy Release ( 3 hrs )

Last week discovered Cabin Lights CB didn't have a wire connected.  Stein Air quickly made appropriate wire w/ terminal & labels, plus provided lacing material and a "Menda Harness Wire Threader" tool (so I could thread wire through already completed laced harnesses) which I rec'd Monday.  So, simply removed CB panel, inserted wiring all the way back to LH side along with other lighting wires (to connect to LED strip under glare shield).   Also used unibit to enlarge hole in IP to 0.50".   Installed SB500-06 in IP so canopy release handle slides through plastic bushing.   I also rec'd order from Stein Air for "forest of tabs" ground plate, faston connectors, plastic protection sleeve.  Next task is to add to inside of firewall.

snap bushing installed for canopy release handle

received parts to install grounding plate on firewall

Firewall Forward Kit

Alternate Air Control Cable ( 1 hr )

Installed Alternate Air Control Cable (emergency opening in air plenum in case air filter is blocked)  per Sect 50-04, Steps 2-10.   Good instructions helped insure operates well.

hardest steps were installing adel clamp attached to
adel clamp on oil line.

Firewall Forward Kit

Throttle & Mixture Control Cables ( 4 hrs )

Worked on several tasks related to IP wiring prep for engine sensors.   Also, after discussion with Nick Millard and Josh Swenson at Stein Air,  I ordered "forest of tabs" grounding plate and related materials.  Then completed installation of Mixture Control Cable per Sect 50-03 and Throttle Cable per Sect 50-04, Step 1.  Both based on Sect OP-22 with brackets and bellcrank assembly details.  Lots of work, but very satisfied with smooth operation of controls.  Yay!

Mixture control ...full Lean, against stop.   Oops, seeing
picture I realized forgot yellow torque seal on jam nut (done).

Mixture control ...full Rich, against stop.

Bottom of engine.  Installed bracket holding Throttle cable. 
Second oops...also had to go back to add yellow torque seal 
to cable retention nuts (done)

Throttle attached.  Shown at Wide Open, against stop

Throttle at Idle...against stop

Firewall Forward and Finish Kit

Seat Back Snaps and Control Cables ( 2 hrs )

Added button Snaps to top of Seat Frames, using template provided by Flightline Interiors.  Snapped cushions onto Seat Frames (stored prior to taking a pic).   Connected Prop Cable at Prop Govenor per Sect 50-03, Step 2, and started installing Mixture Cable per Sec 50-03, Step 3 and Section OP-22. 

Prop Gov connected to cable control.
Works smoothly...

Firewall Forward and Finish Kit

Control Cables and Interior ( 3 hrs )

Installed two Adel cushion clamps to left and right sides of Circuit Breaker Panel.  Added nylon ties for extra support of cables (see pic).  Carefully tightened cable nuts at IP.    Yay !...received large box containing interior from Flightline Interiors (Abby) so unpacking was like Christmas morning.  Lots of unpacking and trial fitting...then Nancy gave a thumbs up !   We like the color and materials really well:  "Condor" vinyl with "Marble" fabric inserts in seats, Marble on upper panels and Condor vinyl on lower panels and armrests.   Black joystick boots with gray stitching.  Charcoal baggage area  and floormats.  [note:  flash pics / fluorescent lighting affects colors ]  Still pending delivery of black seat belt harnesses.  Positioned loosely since not ready for final install.   Sweet !

underneath control cables

Baggage floor mat...loosely positioned

1st mock up installation.   Joysticks and many alum panels not installed, including seat backs

Firewall Forward

Control Cable installation ( 2 hrs )

Installed Throttle, Prop, and Mixture Control Cables, along with Alternate Air Cable per Step 5 and Fig 2 at Sect 50-02.  Since I revised location to bottom of Instrument Panel ( vs hung underneath) to provide greater knee clearance and visibility to Circuit Breakers, I'm pleased routing and clearances worked well.  The special doubler plate providing uniform surface on backside of IP for the nuts was a perfect fit ( links to Jan 17  and Jan 18, 2018 logs showing details). Thanks Stein Air!

Partially assembled...doubler plate in place

Prop Control Cable routed

all four installed !   working great, too.

view with all four installed.  Not fully tightened...yet.

bottom view:  pending tightening adel cushion
 clamps on each side, and addition of nylon ties
(may not be needed, but convenient plate above) 

Avionics

Circuit Breaker Panel and Heater Cables ( 3 hrs )

Installed Circuit Breaker Panel.  Installed RH and LH Cabin Heat Cables per Sect 50-02, Steps 5-7.  Required laying face down in Fuselage to reach.  It was as hard to get my shoulders and arm into position as I'd imagined --aarrggh.   But parts fit and operate well.

eight 6-32 screws installed

yellow arrow on right points to location of heater cable 
connection.  Looks easier from this view than reality to reach
....at least for my 6'4" body

LH side cable connected

RH side

Avionics

More Harness protection and Circuit Breaker Panel ( 2 hrs )

Added 1" dia split flex tubing protection to main harness under radio tray.  Trimmed flanges on backside of Circuit Breaker Panel (actually # F14106 Wiring Channel at Sect 35-10)  per special instructions from Stein Air.  Insures clearance to copper bus bars in circuit breaker assembly. ( wish I'd known prior to riveting Wiring Channel into center area last year !)

top view:  1" dia split flex tubing in center area installed

view from front

special instructions from Stein Air    ...arrgggh !

Avionics

Main Harness supports ( 1 hr )

Installed both brackets for large snap bushings supporting main harness passing through Vertical Supports.

right side

left side

 

Avionics

Instrument Panel main harness ( 3 hrs )

Per discussion with Josh at Stein Air, determined "Discrete 2" wire best re-routed to LH side for Canopy Open Warning, and "Discrete 3" wire routed to center area to connect to  Aux Fuel Pump to enable G3x to display when 'On'.  "Discrete 4" wire and "Volts 2 Hi" wire will not be used, so left them bundled on RH side as originally located.  Created two brackets to mount large SB 1093-15 ( 0.937" inside dia) to add to Center Vertical Supports to support main harness as pass from left to right side.  Now primed, will rivet to Vert Supports next.

template made, ready to cut alum 

1 of 2 completed.  Second one (not shown) was much quicker.

Avionics

Instrument Panel wire protection ( 2 hrs )

Added wire protection at various locations, including edge protection and either split corrugated tubing or spiral wrap.   Lots of exploring options and planning routing.

Avionics

Radio Installation ( 3 hrs )

Just returned from 2 wk "road trip" to Niagara Falls, Montreal, and Quebec City in Canada and Bar Harbor, Maine and Franconia, New Hampshire.  Great fall colors and good time with family and friends.   Now, back to building!  Positioned tray for GTR 200 Radio in center stack.  Drilled 6 holes for mounting to side supports.  Created .038" shims to fill gaps each side and assembled with 6-32 screws. Finally, test fit both Radio and GMC 307 Auto Pilot into center stack.  Tah-dah ! ...good fit.

Shims created - ready to
 install GTR 200 tray.

showing position of shims.  extra length helps in positioning
 during installation.  

G5, GMC307 autopilot, and GTR200 Radio. 
(allen wrench still inserted into retention mechanism)

from overhead,  between vertical supports