Avionics

iPad Mount installed ( 1 hr )

Received iPad mount for Instrument Panel.  Ordered from Sporty's this new "Robust Universal iPad Suction Cup Mount" ( a good value at $40 ) and Ram circle base.  Replaced suction cup with Ram base permanently mounted with four 6-32 screws and locknuts.   The 3.75" arm allows lots of positions.   Pending delivery of  11" iPad Pro...

Vertical orientation

Horizontal orientation.

Partially blocks "glove box", but easily moved for access.

Firewall Forward Kit

Secure Reiff Heater harness ( 2 hrs )

Worked to secure connectors & harness for Reiff Heaters.  Used waxed cord (from harness assembly) to wrap each male to female connector (already snap fit).  Then lots of hi-temp RTV to secure harness to air box/oil sump on bottom of engine - per Reiff recommendation in instructions.  Added RTV to wire connections to sensor and each heater pad for strain relief.   Also cut 1.5" from 16" long SCAT hose to fit from baffle to oil cooler now w/ TCW air valve installed.  No pic, ref April 26, 2018 build log.

RH side with heater pad and sensor

LH side with heater pad.

Firewall Forward Kit

Optimate Battery Charger ( 2 hrs )

Received the "Optimate lithium LFP 4S 5A"  battery charger for the EarthX LiFePO4 main battery, Part No. TM291.  Recommended by EarthX specifically for LiFePO4 batteries.  Automatic test, charge, optimize (cell balancing), test and Maintain modes ( 10 steps).   Decided "making do" with Battery Tender Jr was not ideal.  Also finished RH firewall penetration with layers of firesleeve filled with hi-temp RTV per Sect 51-07.

10 steps shown along bottom

includes direct connection to battery terminals w/  plug. 
Performs all steps without interaction.  

bottom view of stuffed firesleeve

top view.   (messy to stuff  with RTV)

Firewall Forward Kit

Reiff Heaters ( 3 hrs )

Installed Reiff Heaters ( HotStrip Oil Sump Heater System, item HSS) so I can preheat in cold weather.   Reiff provides good instructions.   After trial fit to confirm location for each heat pad and the thermostat, I removed the paint with acetone, then scratched surface w/ scotchbrite.  The included epoxy is thick and tacky...kinda challenging to "corral".   Requires at least 48 hrs at 75 deg.

Reiff HotStrip Oil Sump Heater

removed paint on Oil Sump ( Lycoming IO-390 )

ready to epoxy on heat pads

added more tape after pic, since pad was gradually drifting downward
 ( gravity sucks !)

Firewall Forward Kit

Firesleeves (2 hrs)

Filled inside of firesleeves with hi-temp RTV after adding second firesleeve.   Used SS hose clamps  (vs Vans instructions to wrap with safety wire per Sect 51-07, Fig 3)   Applied self-adhesive label for new Oil Cooler temp control (butterfly air valve at oil cooler).   Stein Air did nice job.  Looks good -- but the camera shows a "white" outline around perimeter that is not apparent to eyeball.

LH firesleeve with hose clamps

 

stuffed full of hi-temp RTV.   (from cockpit side too)

applied new label for Oil Cooler temp control. [ camera shows
a "white" outline around perimeter that is not
apparent to eyeball]

Firewall Forward Kit

Firesleeve #2 and UHMW tape  ( 3 hrs )

While waiting for "anti-short bushings", I went ahead to insert firesleeve into RH tube.  With extreme difficulty (really sore hands!) I managed to get the firesleeve through to other side.  It took a couple hours!   The order of UHMW (ultra high molecular weight) tape arrived from Vans.  Per Sect 49-10, Fig 2,  I wrapped tape around VA-190 braided hose in couple locations.  Attached VA-119 hose to VA-190 hose with 2 cable ties per Sect 49-11, Step 4 & Fig 3.  Today, Rick Olson, builder of RV4 ( 2018 first flight) visited shop to check out my progress and discuss remaining details.  He's got lots of experience and was very helpful. Thanks Rick!

nominal gap for VA-190 to battery angle...
Vans builds have similar (or zero) clearance.

Arrow points to potential contact, now
covered with UHMW tape.  Circled area
is the 2 cable ties (also wrapped 1st
with UHMW tape)

Firewall Forward Kit

Firesleeve ( 2  hrs )

Per Sect 51-07, Steps 1-3 added firesleeve to wire & cable bundle at firewall pass-through (FF00001 Firewall Penetration Fitting).   Called Vans Prod Support - and Mitch Lock answered, President of Vans Aircraft.  He was filling in!  I told him my bundles were so tight in opening, I didn't feel I could insert the rubber firesleeve - especially the RH one.  He described how he encountered same issue, and used "anti-short bushings" instead when he built his RV14a.   Key is isolation of wires from metal edges front and back.   I ordered some 1" dia size (no local stores carry that size).  I inserted firesleeve in LH hole...with great effort, taking over an hour to push in.   I plan to use the bushings on RH side.   Both will be filled with hi-temp RTV, then wrapped with second layer of firesleeve.

Inside view showing success pushing firesleeve 1/4" past edge

Engine side.   Will fill with hi-temp RTV, then add
 another layer of firesleeve.

Engine and Firewall Forward Kit

Oil Cooler Air Valve, EarthX battery BMS ( 2 hrs )

Connected cable at air valve control arm.  Used -12 size cushion clamp on Engine Mount tube to mount a -3 size to constrain cable.   Added redundant collar (positioned to enable opening IF primary set screw loosens), and wrapped extra cable around arm.  Overall, works great.   Added spade connector to brown/blue stripe EarthX Discrete wire = "Discrete in 5" (GAD27, pin 13).  Will configure as "active low".   This enables BMS (battery mgmt system) to signal G3X display condition of overcharging, or over-discharging.

Full open.  Note cushion clamps on engine

mount tube holding cable in position.

Fully closed.  

Connected to BMS signal on EarthX battery (circled in yellow)

Engine and Firewall Forward Kit

Oil Cooler TCW Air Valve install  ( 3 hrs )

Painted semi-gloss black, mounted bracket to bottom IP for Oil Cooler Air Valve (from TCW).  Reference prior build log Feb 2.  Positioned valve on Oil Cooler to align with push-pull cable.   After routing cable through Firewall, I cut cable to length.  (Since not part of Vans instructions, it takes longer examining options and measuring 3 times).   Mounted air valve with (2) AN526 632R6 screws & MS1042 06 metal locknuts.   Sealed with hi-temp RTV.  Temporary attached cable---will finish tomorrow.

Cable control and bracket installed.   
Trying one of several labels Stein Air provided.

Ready to complete cable attachment.  But
first need to secure cable to engine tube with
Adel cushion clamps (where blue tape is now)

Engine

Slick Magneto Service Bulletin SB1-15A

Recently a friend gave me copy of Slick Service Bulletin SB1-15A to check against my engine's magneto (Left, other on right is PMAG).  It was originally published 07-02-15, but recently revised on 11-12-18. This deals with decreased life of distributor gear assembly.   I confirmed my Slick magneto is newer than affected serial numbers.   Mine is Serial No 17090862 (made Sept 2017), whereas affected are through July 2016.   I'm also documenting in my Engine Logbook.

Firewall Forward Kit

VA-190 re-position ( 1 hr )

Dis-assembled elbow from oil cooler for VA-190 hose as'ly.  Cleaned threads, re-applied Permatex high temp thread sealant.  Installed with approx 5 degrees more vertical alignment (any more would cause hose to rub engine mount tube).  VA-190 now just clears battery angle  -- so still need to explore how to prevent contact wear during engine vibration.   I'll ask Vans Prod Support on Monday. (appears on their build they attached hose to nearby fuel line hose with nylon tie to provide clearance)

Firewall Forward Kit

EarthX  ETX680 battery installed, etc ( 1 hr)

Back from winter break in Arizona, so back to building.  Rec'd EarthX680 (LiFePO4) battery.  Only 3.9 lbs, saving about 11 lbs vs lead acid.  Installed with provided closed cell foam pads, retained with same FF01403A Battery Box Angle.  Need to change orientation of oil cooler elbow fitting for VA-190 hose as'ly, since hose interferes with battery box angle.  Per Fig 1, sect 49-07, Step 1 installed at 82 deg, but needs to be few degrees more "vertical".

 

VA-190 hose rubs on battery angle retaining
battery.  Need to re-orient elbow
to change routing