Project Log - July, 2004 

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 February 3, 2021

 Project Log

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 Firewall Forward
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  Finishing Up!

 Project Notes
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July, 2004

July 1, 2004 - 1 hours
Vacuumed out the cabin and started masking stuff off.

July 3, 2004 - 6.3 hours
Finished masking off the airplane and covering up all the things in the shop that I did not want to get painted. I cleaned everything and sprayed the primer and paint on the cabin. It turned out pretty good. I wouldn't be too happy with that kind of finish on the outside of the plane but for the cabin it will be okay.

The airplane goes in the plastic wrap again.

It sure seems like I have done this before.

It's hard to tell the exact color but you can see that it looks much better than the battleship gray primer.

July 4, 2004 - 2.5 hours
I took the panel into my mad scientist lab and tried to get everything wired that I could on the bench before taking it outside to mount in the plane.

July 5, 2004 - 0.5 hours
I decided that I wasn't going to be able to get all the wire bundles to look like I want without having the panel in the airplane, so I moved all the tools and the panel out of the mad scientist lab and into the airplane factory. I mounted the panel in the plane with clecos.

The cool factor rises sharply as the panel goes in.

July 5, 2004 - 3.5 hours
I spent a little time today finishing up a few details that I wanted to get done and couldn't until the panel was in. I made the new throttle and mixture cable brackets. The old ones were made from 062 angle and I wasn't sure they'd stand up to the vibration. I replaced them with 0.125 angle. I also fixed the cabin heat muff. It was loose on the exhaust after tightening the hose clamps all the way. Then I mounted the throttle/prop/mixture/purge controls under the instruent panel and ran the cables through the firewall. I wanted to have those installed before getting too carried away on wiring. Wires are easy to route around control cables but control cables aren't so easy to route around wires.

This is where the mixture (left) and throttle (right) cables go through the fuel pump / cabin heat cover. This photo makes it look like those are really sharp bends but they are not as bad as it looks.

This picture shows the throttle cable coming through the firewall, and attaching to the AFP servo.

July 6, 2004 - 2.4 hours
Finished up the control cable support bracket that attaches the control cables to the sub panel. Started running wires. I had to punch a few holes and I think I spent more time scratching my head trying to figure out where the wires are going to go than I did running wires.

July 7, 2004 - 1.75 hours
Spent most of the evening soldering really small wires to the back of the intercom.

July 8, 2004 - 3.2 hours
I have to leave to go offshore later today so I decided to piddle around with the plane some. I mounted the GRT manifold pressure transducer to the sub-panel and finally got around to installing the bulkhead fitting and the hose to the manifold pressure port on the engine. I tubed up the line to both the manifold pressure sensor and the Lightspeed electronic ignition. I cut some more holes in the firewall for the electronic ignition cables as well as some other wires.

I took this picture of the Manifold Pressure sensore because the way I'm mounting it this sticker will be covered up and I need those numbers to calibrate it.

Here you can see the hose going from the manifold pressure port on cylinder #3 to the bulkhead fitting.

This is a shot of the Lightspeed Electronic Ignition box and the manifold pressure sensor for the GRT EIS-4000 engine monitor.

July 21, 2004 - 3.5 hours
Connected the Mixture, Governor and Purge control cables to the AFP and prop governor. Reinstalled the fuel tank vents (hopefully this will be the last time). I also started scratching my head trying to figure out the best way to get the cabin heat control cable through the firewall without interfering with too much stuff. The jury is still out.

July 24, 2004 - 2.5 hours
Started working on mounting the magnetic sensor for the Dynon D-10.

July 25, 2004 - 6.5 hours
Finished mounting the Mag sensor and pulled all the wire to wire it up. Also finished all the power wiring to the Dynon. Finished wiring up the Lightspeed Electronic ignition and the strobe power supply stuff as well.

I made a couple of little U-brackets out of stiffener material. They have to be at an angle because the magnetic sensor needs to be in the same orientation as the EFIS. And the panel is at an 8° tilt from the rest of the plane.

Here you can see the Dynon OAT probe. This will allow the EFIS to display OAT, True Airspeed and Density Altitude. It's back here because the interface requires it to be wired to the magnetic sensor.

Here is the magnetic field sensor for the Dynon EFIS D-10. This thing will tell the Dynon which direction the airplane is pointed. There is a magnetometer (the technical term) inside the D-10 but the word on the street is that this works better.

And here is the final product installed complete with a space age moisture barrier. That would be a zip-lock bag and a ty-wrap.

July 27, 2004 - 1.75 hours
Mounted the brain box for the Proprietary Software Systems AOA indicator. Glued some more of those little stick on wire holders to different places on the panel.

I mounted the AOA box with some left over stringer material.

July 28, 2004 - 0.8 hours
Wired up the master contactor to the switch and turned it on. After checking that all the right voltages were going to all the right busses I checked the pins on the connector for the Dynon and then put a fuse in and turned it on.

It's Alive!!! After checking a few things I put the fuse in for the Dynon D-10 and turned it on. This is too much fun.

July 29, 2004 - 1.2 hours
Wired up the Aux feed to the essential buss. This is the switch that feeds the e-buss if the master buss is down. I also piddleed around with that cabin heat cable again.

July 31, 2004 - 5 hours
Today I built a bracket and hooked up the parking brake cable. I started wiring the AOA indicator. I also hooked up the static an pitot lines to the AOA and the Dynon. While I was in the back of the plane I pulled the rudder cables back through the cabin again.

Here you can see the static and pitot connections to the back of the Dynon. The other fitting is for the Dynon AOA which I am not using.

I made a simple bracket from some angle stock that I had around for the parking brake valve. The small brass 'knob' on the cable is just a stop to keep me from pulling the valve handle over center.

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 February 3, 2021