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

 

Finish Kit and Avionics

Safety wire and Oil Cooler Air Valve ( 3 hrs )

Finished safety wiring Main Gear Brackets for Wheel Fairings. Determined .032" vs .041" wire is much easier with these smaller bolts, closely spaced.  Started revision to Oil Cooler to add a 4" butterfly air valve to control oil temp in cold air.  [I got a good deal on mine when a friend determined he couldn't use his].  Drilled .047" hole through the lever arm & rod of the valve, so I could "pin" the arm using .041" SS safety wire.  This adds security since otherwise the arm is secured only by a small bolt clamping on the round rod.  It wasn't easy drilling with this tiny diameter drill, but going very slowly worked - glad the parts are aluminum.   Set the arm so it travels from -45 deg closed, to +45 deg open.   Since I had not used F-14107 bracket to mount the Throttle, Prop, Mixture controls below the panel (instead mounted at bottom of IP, through the panel), it was available to create a much smaller bracket.  After deburring, I mounted under panel to right & below the Mixture control.  It's a straight path out the firewall hole, then large radius brings it to Oil Cooler valve control arm. 

Completed safety wiring bolts for wheel fairing brackets 

Bowden (push-pull) cable,  existing
4" duct, and new TCW air valve

after drilling hole and "pinning" arm to rod w/ safety wire

approx position of air valve, angled to
align with control cable

closed position

sacrificed unused F-14107 bracket to make small one

mock up fit.   Will add label above  (Push to Cool Oil)

View from LH side.  Will prime and paint next

Avionics

Flap Motor connectors, Safety Wiring ( 2 hrs )

Crimped on connectors for Flap Motor.  Added spiral wrap protection and secured with cable ties.  Ready to enclose now with cover.  Started to safety wire bolts holding Wheel Fairing brackets on Main Gear.   First checked torque to confirm done, since hadn't marked with torque seal.

Flap motor connected.  Shown in end of travel

Decided to leave wheel fairing brackets on for first
 flight...so I went ahead and safety wired.

Avionics - Nav and Tail Lights

Tail Light installation ( 2 hrs )

Preparing to install Tail Light per OP56, I discovered this Suntail #LN-201-1 included Molex 5 pin connector.  But I only needed a 4 pin.   So I switched the unused Molex 4 pin connectors supplied with the Nav Light LN-201-1 to the Tail Light, and used the 5 pin connector for the RH Wingtip Nav Light (only 1, but better than none - see Jan 28 log).   Assembled  the 4 pin Molex for L1082 coming from aft fuselage (part of WH00057 harness).  [ note:  WH00057 harness already had female pins crimped - opposite of how Vans instructions showed.  Simply reversed connector and pins]   Crimped male pins/assembled 4 pin Molex to Tail Light.  Attached to Rudder Bottom Fairing w/  4-40 screws (strangely, Vans did not provide these screws in kit)

Switched 5 pin from Suntail so at least 1 Wing Tip -Nav Light
has a connector that matches the connector in Wing Harness

WH00057 harness from fuselage:  crimped on ring terminal for ground wire, and 4 pin connector with female pins

Tail Light with male  4 pin Molex

Suntail LN-201-1 Tail Light
installed.  Note drain hole
oriented toward bottom.