Van's Aircraft RV-9A experimental aircraft kitplane

Mike Hoover's Van's RV-9A
Aircraft Construction Log

Home - Mike Hoover's Van's Aircraft RV-9A Construction Website
Send me an email
Support ACLog.com/rv-9a
My Aviation Blog
Track N2878L with APRS

Aviation Weather Services
NOAA Weather
AOPA Weather
METAR and TAF Retriever
>>Weathermeister.com<<

Flight Planning Tools
AOPA Flight Planner
AirNav.com
SkyVector.com

Aircraft Construction
Empennage
Wing
Fuselage
Firewall Forward
Finish
Supplies
Tools
Journal
Reference Materials
Flight Instruments
Miscellaneous
Workshop
Electrical
Hangar

Van's Aircraft Builder Discussions & Info
Matronics
Matronics Wiki-pedia
Van's Air Force
Yahoo RV-7/7A/9/9A  Group

Aircraft Parts Vendors
Aerocraft Parts
Avery Tools
Aircraft Spruce
Brown Tool
Cleaveland Tools
Genuine Aircraft Hardware Co.
SteinAir, Inc.
Wicks Aircraft Supply
Van's Aircraft
Yard Store Aviation Tools

Aviation Memberships
AOPA
EAA-242
EAA-242 on Facebook
Experiment Aircraft Association (EAA)

Getting Started
Preparing the old workshop
Tooling up
Sheet Metal Practice
Priming Info
The new workshop
Moved project to hangar

Van's Aircraft Builder Websites
Don Alexander - 9A
Mike Schipper - 9A
Matthew & Sandi - 9A
Andy Karmy - 9A
www.n2prise.org - 9A
Paul Eastham's - 9A
Bill's Aircraft Factory - 9
Vern Little - 9A
Dan Checkoway - 7

Misc. Fun Aviation Stuff
APRS Aircraft Moving
Amateur Radio (Ham) License Info
ClearanceWiki.com
A visit from a fellow Van's Aircraft builder
Completed Van's Aircraft 9As - Thanks Clay!
South Carolina Breakfast Club (SCBC) 2010 Schedule

Other Aircraft Kit Builders
EAA242'ers Dan & Jerry's
KR2 WannaBee

Utility Scripts
RivetSizer 1.0
Mortgage Calculator

KCUB 050053Z AUTO 00000KT 10SM CLR 24/12 A2990 RMK AO2 SLP124 T02390122 TSNO

Official time building my Vans RV-9A: 1893.84 hours.


Building time for Firewall Forward: 114.5 hours.
Number of records for Firewall Forward: 39.

2010-09-01 Hours: 5 Category: Firewall Forward Manual Ref: ID#: 1099
Exhaust bracing installation
Wrestled with the exhaust bracing installation. With the cowling installed, I positioned the exhaust pipes even distances from the engine mount and the cowling. I slide the huge exhaust clamps up the pipes first, the I put spacers between the exhaust and the engine mount and secured temporarily with tie wraps. I removed the cowling and sat there for awhile trying to figure out how to proceed. I determined that I must get the cross member installed first. I positioned the exhaust pipe clamps on each side so the flat flange is faciing side up, then measured the distance between the two clamps' bolt holes. I cut enough off each SS tube piece so that the assembly fit. I had to use 3/4" spacers on each side to raise the cross member enough to clear the mixture cable. After the cross member was securely installed, I installed the two assemblies that attach to the engine sump bolts. These were too long to start with as well, so I removed the lower piece of SS tubing and cut off some to make it line up with the bolt holes in the exhaust pipe clamps. The real cuss was to get the washer and nut on these bolts. I used big pliers to squeeze the clamp together to get the bolt fastened. A better idea was brought up to me after I was done: use safety wire and safety wire pliers to squeeze the clamp together. Great idea Tom! I'll have to remember that when working on tough adel type clamps in the future.
Photos:
The exhaust bracing installed. Whew!
[Top]
2010-08-31 Hours: 3.5 Category: Firewall Forward Manual Ref: ID#: 1098
More cowling work
Laid up some little squares of BID cloth on the inside lower corner of the bottom cowling between the vertical and horizontal hinges. This area needs shaving on the outside as it sticks out and does not form a nice transition from the cowling to the fuselage. I laid up 5 layers. After setting up, I trimmed the edge and sanded smooth and reinstalled the cowling on the airplane. It looks as though I will need to add a few more layers once I sand the corner even with the fuselage. Also installed the platenuts and screws in the cowl halves at the spinner.
Photos:
Five layers of BID glass so far in the bottom right corner of the bottom cowling
The bottom right corner of the cowling does not match the fuselage.
Screws and platenuts installed in the cowling at the spinner.
[Top]
2010-08-29 Hours: 3.5 Category: Firewall Forward Manual Ref: ID#: 1097
Installed cowl ducts and hinge pin anchors
Sanded the areas of the cowl ducts and the upper cowling where they would bond together. Then mixed up some epoxy and painted the bonding areas on both the cowl ducts and the upper cowling, then clecoed the cowl ducts to the upper cowling, put the cowling back on the airplane to set up overnight. Also cut some hinge pieces to anchor the upper/lower cowling hinge pins to the front of the cowling per plans. I drilled holes through the firewall so the hinge pins will go through.
Photos:
The cowl ducts "roughed in" to the upper cowling.
Another view showing the upper cowling's nice and shiny smooth inside coat.
[Top]
2010-08-28 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1096
Epoxied the inside of the cowling halves
Mixed up a 50/50 solution of epoxy and acetone and painted the insides of the cowling halves with two coats. Each coat dried to touch in about two hours. I put the cowling back on the airplane to set up over night.
Photos:
The bottom cowling with inside coated in a thin shiny smooth layer of epoxy.
[Top]
2010-08-18 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1095
Misc. cowling stuff
Did some tweeking on the lower cowling support bracket. Removed it and trimmed some excess metal off where it meets the engine mount gusset. It was easier getting the bracket back on without the lower cowling in place. I cut the bottom hinge pins to length and bent them to fit. To do this I first inserted the pins in the hinges and marked where they should bend, removed them and bent them with a hammer with the pin in the table vice. I also starting mulling over the installation of the inlet ducts. Looks like fun ahead!
Photos:
A rear right view of the lower cowling support bracket attached to the airplane.
A view from front left side of the lower cowling support bracket attached.
[Top]
2010-08-16 Hours: 4.5 Category: Firewall Forward Manual Ref: ID#: 1094
Bottom cowling support bracket work
Managed to get the bottom cowling support bracket (or what ever it is called) assembled. This was like putting a puzzle together. The trickiest part is getting the bend correct on the part that connects to the engine mount gusset. Had to call it quits early, so I hope to finished this tomorrow.
[Top]
2010-08-15 Hours: 3 Category: Firewall Forward Manual Ref: ID#: 1093
Bottom cowling work
Trimmed the extra fiberglass from the exhaust recess area so it is even with the rest of the bottom aft edge. Since my slot for the nose gear is wider, I had to make the pieces for the support structure from stock material. Not much to show for the time I spent today.
[Top]
2010-08-14 Hours: 4.5 Category: Firewall Forward Manual Ref: ID#: 1092
Riveted the hinges on the bottom cowling and installed oil access door
I finished up riveting the hinges today. I got all six hinge pieces riveted to the bottom cowling. I also installed the oil access door. Locating the door latch hardward on the cowling was a bit tricky. Not a lot of margin for placement as the aft one might interfere with the thicker part of the cowling if placed to far aft. Also, make sure to install the latches so the little butterfly handles are oriented fore to aft when latched to reduce drag.
Photos:
Front shot of the cowling with all the hinges riveted on.
The oil access door installed.
Starting to look like an airplane!
[Top]
2010-08-13 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1091
Riveted the hinges on the upper cowling
Riveted the hinge pieces on the upper cowling. I mixed up some epoxy and microballoons to help secure the hinges. This was a little messy but not a bad task. Once I had all four hinges rivets on, I put the cowling back on the airplane to let it cure overnight.
Photos:
Right side upper cowling hinge riveted.
The hinge pin installed. Need some cosmetic work here.
Starting to get rid of all the clecoes!
[Top]
2010-08-11 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1090
Drilled upper cowling side hinges
Drilled the upper cowling side hinges. Also made new hinge pins for the lower cowling to firewall four hinge pieces. The ones I had were aluminum. I found two lengths of steel hinge pin and realized that the instructions said to use the steel ones, not the aluminum ones that came with the hinges. I think I am ready to start mixing epoxy and microballoons and do some riveting!
Photos:
The upper and lower cowling side hinges are drilled and clecoed.
[Top]
2010-08-10 Hours: 4.5 Category: Firewall Forward Manual Ref: ID#: 1089
Lower cowling trimmed along the sides
Long hot day! I trimmed the flanges from the upper edge of the lower cowling. Checked the fit to the upper cowl and adjusted a few areas. The fit looks good. I drilled the hinges to the bottom cowling and ground out the area near the front so the hinge pins could be inserted. Drilling and clecoing the hinges took some thought. It goes from centered eye at the fore to eye above edge at the aft, so you have to consider edge distance when drilling the hinge as it changes from too high to too low fore to aft. I marked a line along the edge of the lower cowling fore to aft about 23/64". This allow my best chance to stay within edge distance as I drilled the hinge from aft to fore. I also riveted in a short piece of mock hinge on each side of the fuse/firewall above the hinge that joins the upper and lower cowls and up to where the side and top skins join. This will keep the cowling in that area from being pushed. I used an .020 shim and some .040 to mimic the hinge for this. The pieces only covered three rivets, so they were only about 2 3/4" long.
Photos:
The hinge drilled and clecoed to the bottom cowling.
Left side showing the fit of the cowling.
Right side showing the fit of the cowling.
[Top]
2010-08-09 Hours: 4.5 Category: Firewall Forward Manual Ref: ID#: 1088
Moving right along on the cowling
A long productive day. I got the lower cowling aft edges trimmed to fit, then riveted on the bottom and side hinges. I used a strap clamp to hold the upper and lower cowling halves together nice and tight while working at this stage. I drilled and clecoed the upper cowl hinge rivet holes. I marked the cut line along the upper and lower cowling overlap fore and aft trim line. Everything is drilled and clecoed except the fore to aft hinges that connect the upper and lower halves. I removed the 1/4 plexiglass spacer from between the upper cowling and spinner to see the result. It is really tight! About 1/8", so I was surprised that it didn't come out to the 1/4" space that I thought I was building into the set up. The space at the bottom is almost 5/16". I will wait until after I have the engine running to see if I need to work the spinner area of the cowling for a nicer fit.
Photos:
The right side lower corner area needs some altering to get the fit right.
The strap clamp helps hold the cowling halves together nicely.
Is it level yet? I hope so. All cowling hinges are drilled and clecoed.
[Top]
2010-08-08 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1087
More lower cowling work
Had to remove more material from the right side of the slot in the bottom because the nose gear leg is close on that side when the lower cowling was taped into place on the airplane. I cut the overlap material from the aft edge of the lower cowling to around the curve. Now only the sides need trimming at the aft edge. I think I'm getting close!
Photos:
The right side lower canopy trimmed at the bottom to fit against the bottom skin
This airplane has nice lines that are starting to shape up!
Is it level? I hope so because that's about as good as I can get it!
[Top]
2010-08-07 Hours: 3 Category: Firewall Forward Manual Ref: ID#: 1086
Upper and lower cowling fitting at the spinner
After talking with a few RV builders now flying about how to proceed with matching up the cowling halves at the spinner, I decided to just start hacking with the cutoff wheel. Yikes! I removed the front and interior flange at the spinner from the lower cowling, leaving only the flange that will hold the nutplates to hold the two halves together. After some other trimming, I got the halves clamped together, making sure they are on the same plane at the spinner, and drilled #40 holes and clecoed them together. After fitting on the airplane, it seems the lower cowling wants to pull the upper cowl off a bit - I thought I had it fitted perfectly. Plenty of tweaking still ahead.
Photos:
The two cowling halves on the airplane. Still plenty of tweaking to come.
[Top]
2010-08-06 Hours: 2 Category: Firewall Forward Manual Ref: ID#: 1085
Cowling along
Test fitted the lower cowling and marked the aft edge cut line - not alot of overlap to start with compared to the upper cowling. Had to cut another 1/4" of material from the right side of the nose gear slot as the cowling rubbed up against the nose gear leg when fitted into place. I have gotten the spinner area matched up on the two cowling halves yet. Need to do that to continue on.
Photos:
The lower cowling test fitted into place on the airplane.
The cylinder #3 EGT probe has plenty of clearance from the cowling! Yeah!
[Top]
2010-08-05 Hours: 5 Category: Firewall Forward Manual Ref: ID#: 1084
Lower cowling hings installed on firewall
Installed the lower hinges on the firewall. Cut the slot in the lower cowling for the nose gear. Had to pretty much eyeball where the middle was to mark and cut the slot. After test fitting it to the airplane, I will have to cut about another 1/4" off the right side of the slot as the cowl rubs the gear leg as is. Still need to get the upper and lower cowlings to fit at the spinner.
Photos:
The lower right side hinge installed on the firewall.
[Top]
2010-08-04 Hours: 1.5 Category: Firewall Forward Manual Ref: ID#: 1083
Started on the lower cowling
Tried to modify the lower cowling to get it and the upper cowling to fit together at the spinner. Some modification will definitely be required. I removed the flange from the outer part of the air intakes to get the fit. Some material will have to be removed from the underside of the upper cowling to get them to fit together nicely. A lot more work to get this task done.
[Top]
2010-08-03 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1082
Got the upper cowling hinges done and trimmed the aft edge of the upper cowling
Got the two hinges along the upper cowling/top fuse skin done. Bevel the cowling hinge pieces and deburred them. Also trimmed the aft edges of the upper cowling to fit nicely. There is a 1/16 or less gap between the top fuse skin and the upper cowling to allow for paint.
[Top]
2010-08-02 Hours: 2 Category: Firewall Forward Manual Ref: ID#: 1081
Drilled and clecoed the upper cowling hinges
Drilled the upper cowling hinges to the fuse/firewall. Removed them and dimpled the .032 shims and countersunk the hinges.
Photos:
The upper cowling hinges drilled and clecoed to the fuse/firewall.
[Top]
2010-07-31 Hours: 3.5 Category: Firewall Forward Manual Ref: ID#: 1080
Upper cowling work
I positioned the upper cowl to where it is level with the airplane, marked a few reference points so I could get it back into that position. I marked the aft cut line and cut that off with the cutoff wheel. Sanded the edge smooth. I drilled and clecoed the right side length of hinge along the top fuse/firewall.
Photos:
The upper cowling final fitted before marking the aft edge for trimming.
The right side length of hinge drilled and clecoed to the firewall/top fuse skin
Under the cowl view of the upper right side hinge clecoed to the firewall/fuse.
[Top]
2010-07-30 Hours: 3 Category: Firewall Forward Manual Ref: ID#: 1079
Cut oil filler door hole in upper cowling
I cut the oil filler door opening in the upper cowling. Smoothed the edges first with a file, then will some really fine grain sand paper. Edges are as smooth as glass. Sized the oil filler door to fit and did some re-working on the hinge pieces to get them to fit better. I removed the aft tab on the cowl side hinge piece that I had left on their for more mounting area because it interferred with an area of thicker cowl nearby. Made some .040 shims for each hinge piece to help lower the profile of the hinge eyes. Did some more head scratching and studying before trimming the aft edge of the upper cowling. I want to make sure the upper cowl is level before marking the aft edges for trimming.
Photos:
The oil filler door opening cut out of the cowling.
[Top]
2010-07-29 Hours: 3 Category: Firewall Forward Manual Ref: ID#: 1078
Upper cowling started
Marked the 2" line around the firewall on the top, sides, and bottom fuse skins. Cut the oil door to size and cut the hinge to fit. I marked the cowling for the oil door cutout. Placed the cowling on the airplane using the spacer tool Tom lent to me to get the proper 1/4" spacing between the cowling and the spinner aft bulkhead.
Photos:
The upper cowling test fitting into place with plexiglass spacer up front.
Oil door with hatch marks to indicate the cutout area.
The oil door hing is cut to length and ready to install.
[Top]
2010-07-26 Hours: 2 Category: Firewall Forward Manual Ref: ID#: 1077
Assembled battery and ground cables
Assembled the positive terminal battery cable. Crimped the lugs on each end. Test fitted to the firewall. Not sure where I will anchor my negative cable yet, so I only put one lug on it so far.
Photos:
The positive terminal battery cable test-fitted onto the firewall.
[Top]
2010-07-21 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1076
More firewall forward tinkering
I think I have the Red Cube fuel flow transducer install, so now on to something else. I did a lot of head scratching and tinkering about, reading the manual and looking at the engine. A lot yet to do! I went ahead and torqued the exhaust pipe flange bolts. I do not think I will be removing the exhaust system again. I had to loosen the EGT sensor probe pipe clamps in order to get the socket on the nuts. I used a universal joint type extension to get to them and torqued them to 12.5 foot pounds. Next I safety wired the oil dip stick tube to the engine block. I pulled the throttle and mixture cables off the shelf and noticed some rubber boots on were cracking and splitting. Yikes! Shelf wear? I fellow builder told me not to worry about it, his fell off along time ago - not an issue. Still not cool though.
Photos:
Cracking rubber boots on brand new throttle and mixture cables.
The oil dip stick tube safety wired to the engine block.
The fuel hoses installed from the engine pump to the carb. I think it's done!
[Top]
2010-07-20 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1075
Finished a fuel hose and installed the tach sending unit
Installed the UMA tach sending unit into the left mag with the help of Ron Shelton - glad he dropped by! The thing is rather difficult to install and Ron helped unwind the wiring as I turned the wrench. Thanks Ron! Then I moved on to finish making the fuel hose that goes from the fuel pump to the Red Cube fuel flow transducer. I had to cut the fire sleeve a bit and re-dip that end, clamped it on with some Aeroquip clamps (ACS PN: 900591B-1C). Removed the exhaust pipes enough to place the carb heat muff onto the exhaust pipe. Other misc. tinkering as well.
Photos:
The newly assembled fuel hose from the pump to the Red Cube fuel flow transducer
[Top]
2010-07-17 Hours: 3.5 Category: Firewall Forward Manual Ref: ID#: 1074
Made a fuel hose
I had to make my own fuel hose that goes from the fuel pump to the Red Cube fuel flow transducer. The length of SS braid (816) fuel hose was 8.875". Van's pre-made hoses are too long. As with anything else to do with the project, I was completely unknowledgable about doing this. So I delved in, bought the parts from Vans. I installed a fitting on one end of a length of SS braided fuel hose and installed this on the fuel pump fitting. I worked the fuel hose over to the Red Cube and marked a cut line. I wrapped masking tape around the fuel hose several layers nice and tight and centered on my cut line. I put this in the table vice, clamping only enough to hold the fuel hose snuggly and cut the fuel hose with the cutoff tool - the same one I cut the canopy with. The masking tape keeps all the SS braiding from getting out of control. I removed the tape and installed the other fitting. I cut a length of fire sleeve about 3/4" longer that the length I measure off the new fuel hose assembly. This will help accommodate the radius bend from the fuel pump to the Red Cube fuel flow transducer. To seal the ends of the fire sleeve so they will not soak up oil, fuel, and debris, I made a batch of dip: I filled a baby food jar half way with MEK (used air mask) and then squeezed in about a foot long drop of red high heat Permatex RTV. This was really experimental. I had to mix this for about 15 minutes to get all the RTV to dissolve into solution. The consistency was like tomato soup or perhaps slightly thicker. Once mixed I dipped the ends into the jar, swirling around gently and holding it in there for about 10 seconds or so to make sure the fiber lining in the fire sleeve soaked up ample dip solution. Once removed I let the excess drain out onto some card board with gentle shakes. I repeated the dipping process for the other end and let cure for about 45 minutes and then repeated the dipping process. This seems to have worked really well. The fire sleeve ends are sealed very well and there is enough flex to installed the fuel hose. I practiced clamping the ends with Aeroquip strap clamps but goofed them up, so I will order a couple more and get it done right.
Photos:
My newly assembled Aeroquip fuel hose and fire sleeve dipped with RTV/MEK.
The fire sleeve ends are well sealed the the RTV/MEK dipping solution.
[Top]
2010-07-13 Hours: 1.5 Category: Firewall Forward Manual Ref: ID#: 1073
More firewall forward work
Received the proper AN363 lock nuts from ACS along with a bunch of other supplies that I will need to get the FWF done: lots of adel clamps, AN3-3A, 4A, and 5A bolts, nuts, and washers, and the battery. I installed the battery into the battery box. Also installed the Red Cube bolts with the lock nuts and safety wired it. Seems like I am moving along slowly, but I sure am spending a lot of time researching and learning where FWF wiring and other things will go. I think it is time to start working on getting the cowling fitted.
Photos:
The battery installed in the battery box.
The fuel and oil pressure sensors installed.
The final install of the Red Cube fuel transducer with safety wire.
[Top]
2010-07-11 Hours: 2 Category: Firewall Forward Manual Ref: ID#: 1072
Installed the Dynon EGT sensor probes
After pouring through as much info as a could find on how others have installed their EGT probes, I elected to install them two inches from the exhaust flanges. The right side two probes for cylinders 1 and 3, I angled the sensors about 30 degrees forward. With cylinder 1, the probe is on a curved portion of the exhaust pipe, but this cannot be avoid in any configuration on at least one of the cylinders. With the left side 2 and 4 cylinders, I angled the probes about 30 degrees aftward. To locate each hole, I used a spare hose clamp with a #40 hole drill in it on the center line of the band to use as a drill guide. I tapped each exhaust pipe through this guide at #40 and went back and enlarged them to 1/8" per Dynon's install guide, deburred, and put the probes in the holes and tightened the band clamps. On the curve pipe of the #1 cylinder, I located the hole a little lower so that the tip of the probe would end up 2" below the exhaust flange. It angles up, so if I had just marked a 2" location on the pipe and installed there, the probe tip, pointing at an upward angle, would end up 1/4" or more above the 2" mark.
Photos:
Right side of engine showing the location of the EGT probes angled forward.
The left side of the engine showing the EGT probes angled aftward.
[Top]
2010-07-10 Hours: 4.5 Category: Firewall Forward Manual Ref: ID#: 1070
Installed sensors and a bunch of head scrathing and thinking
Installed the CHT sensors, carb temp sensor and began working on getting the EGT sensors installed. This is a bit tricky as Dynon says to installed the EGT sensors between 2 and 8 inches from the exhaust flanges and all the same distance and on straight portions of the exhaust pipes. This situation does not exist on the Vetterman exhaust that satifies all four sensor positions. More research on this to come.
[Top]
2010-07-09 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1069
More firewall forward stuff
Got the Red Cube fuel flow transducer mounting bracket finalized and mounted on the firewall. I chose to stay with the thicker 3/16" angle since I already had it fitted. I added two more bolts to the firewall so that the bracket flange would be tight up against the firewall. With only the two bolts through the diagonal firewall stiffener, there was a gap in the corners of the bracket and the firewall that I was concerned might collect gunk or debris over time behind the angle bracket. Also drilled a lightening hole in the horizontal flange that the Red Cube sits on. I have AN363 stop nuts on order to use in place of the nylock nuts that are shown in the pictures.
Photos:
The Red Cube fuel flow transducer mounting bracket bolted to the firewall.
The fuel line from the Red Cube to the carburetor installed.
I used a cable tie stand off from the engine mount to dampen vibrations.
[Top]
2010-07-06 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1067
Worked on installing the Red Cube fuel flow transducer
I haven't log time here in a while, but I have been spending hours mulling over the firewall forward installations. Today I worked on getting the Red Cube fuel flow transducer installed. I decided to mount the red cube on the left side of the firewall between the fuel pump and carb. The photo show a hefty 2.5 x 2 x 3/16" piece of angle - it's what I had on hand. The long "walrus tusk" bolts are just temporary while I wait for my shipment of parts. The angle mount bracket is attached to the firewall with two countersunk #10 screws through the firewall stiffener angle. I will put some lightening holes in the angle, or may replace it with some 1/8" angle that I have on order. This placement will require either a 45 or 90 AN fitting entering the red cube and a 45 degree fitting exiting the red cube. Also, the flow is just below the carb so I am adhering to the directions by not having the flow go down out of the red cube. I had first wanted to mount it above the gascolator but a few folks seemed unhappy with this. Inside the cockpit puts it on the wrong side of the of gascolator so I choose the location that some folks seem to think will work best for my set up. I am done with the fuel lines inside the cockpit, so I am not wanting to go back and redo a bunch of that to accomodate the red cube. Would have been nice to know that I would even have to install a fuel flow transducer a good while back, but that's kit building!
Photos:
Red Cube fuel flow transducer test-fitted on an angle installed on the firewall.
[Top]
2010-03-18 Hours: 1 Category: Firewall Forward Manual Ref: ID#: 1033
Painted the battery tray assembly
Painted the battery tray assembly and strap with some semi-gloss "Deluxe" black high heat paint. Probably overkill, but I needed some to touch up my BBQ grill at home.
Photos:
Battery tray assembly painted and mounted on the firewall.
[Top]
2010-03-16 Hours: 2.5 Category: Firewall Forward Manual Ref: ID#: 1032
More F-7127C retainer strap work
Got the lightening holes drilled in the F-7127C retainer strap using a unibit. I had to buy a new one because my old one gave out at the 1/2" drill - dulled out I suppose. Not bad after seven years. I primed all of the battery tray components and plan to paint them with some high temp black paint.
Photos:
The F-7127 battery tray assembly attached to the firewall.
[Top]
2010-03-11 Hours: 3 Category: Firewall Forward Manual Ref: ID#: 1031
Finished battery box assembly, started F-7127C retainer strap
I did not like the tight, forced fit of the three F-7127 battery tray assembly bolts to the firewall. It took way too much force to get the bolts in and tightened. I removed the battery tray from the firewall, removed the three nutplates from the F-7127A side angles so I could see how the bolt holes line up with the firewall. The two left ones line up perfectly as I would have guessed. The right hole did not line up. It was off by about 1/16". Warning: match drill this hole; don't just removed the rivet from the firewall and hope it lines up. I had to wallow out some of the firewall/stiffener to get the bolt to fit. Seems to be okay. Also started fabricating the F-7127C retainer strap. I marked the centerline, drilled one of the bolt holes, then match drilled the other to the battery tray assembly. I cut the strap to length - mine was not exactly to the measurements on the DWG 31A, so do not cut the bar to length first, get your bolt holes drilled as I mentioned above, then cut to length. I marked and drilled pilot holes for the lightening holes. I tried one with a 3/4" holes saw - it's a little wild. I will use a unibit for the remaining ones. I also cut the radius on the corners of the strap with a 1/2" radius, using a 1" dia. hole template.
[Top]
2010-03-11 Hours: 4 Category: Firewall Forward Manual Ref: ID#: 1030
Worked on battery box assembly
Drilled and clecoed the F-7127A's to the battery box. I used a strip of .020 under the left one per plans as a shem to simulate the F-601K-1 firewall recess flange. Deburred everything, dimpled the battery box rivet holes, countersunk the F-7127A's and primed the exposed steel on everything. I had installed the nutplates but had to remove three of them while riveting the F-7127A's to the battery box because they were in the way. So, rivet the nutplates on last. I bolted the battery box assembly to the firewall. It was tough to get the bolts started as they do not line up perfectly with the holes in the firewall. It might have been better to match drill through the nutplates into the firewall, but I had earlier drilled out the rivets in the firewall and enlarged the holes to #12 for the AN3 bolts.
Photos:
Drilling and clecoing the F-7127A-L to the battery box with .020 strip under it.
Battery box assembly bolted to the firewall.
[Top]
2010-03-03 Hours: 1 Category: Firewall Forward Manual Ref: ID#: 1029
Installed master and starter relays and copper bar
I installed the master and starter relays, bolting them to the firewall. Then I cut to length and drilled the holes in the copper bar strips. After trying to fit the copper bar strips, I had to remove some flange material per the drawing from the lower left flange of the master relay. Then I reinstalled, tightened the copper strips on both the relays, then tightened the bolts on both relays to the firewall. I measured the centerline distance between both relay bolts to make sure of the length I needed to cut the copper strips. It is not exactly like on the drawing, so measure your actual situation before cutting and drilling the 5/16" holes. Drilling the holes was easy with the thinner unibit on my drill press.
Photos:
The master and starter relays installed on the firewall with copper bar.
[Top]
2009-10-27 Hours: 0 Category: Firewall Forward Manual Ref: ID#: 1027
There be engine here!
So I leave Pam and baby at the hospital Tuesday morning to run some errands and do some paper work at home when I get a phone call from Peggy at the FBO. She said, "You have a shipment. There is an 18-wheeler here with an engine." I said, "Stall them, I'll be there in 15 minutes." And so I was out the door, running with no sleep. The FedEx delivery truck was parked on Jim Hamilton Blvd out in front of the FBO and the driver was sitting in the back on top of the engine box. LYCOMING was very visible from a good distance away! He helped me get it in the back of my pickup. I drove thru the gate and headed for my hangar. Uhhh...how am I going to get this engine out of the truck? Lucky for me, Xen, Jack and Allen were there and helped me slide it down a makeshift ramp of two 2x4's. And there the engine box sat in my hangar, glowing white. There was the great temptation to open it up, but I knew I needed to get back to the hospital so I would wait until another day to come open the box and ogle at the Lycoming blue engine. It's been a great week so far!
[Top]
2009-09-04 Hours: 1 Category: Firewall Forward Manual Ref: ID#: 1018
Finishing up slider canopy work
Countersunk the rivet holes where the C-666 aft skirts over lap the C-660 side skirts. Pondered over what else I need to do before I start disassembling everything to prep it for painting. Hopefully, I'll have some Jetflex here next week so I can get everything painted and reassembed.
[Top]
2009-09-03 Hours: 0 Category: Firewall Forward Manual Ref: ID#: 1017
My prop arrived today!
My Sensenich FP prop arrived today. I think it may have survived its trip despite UPS delivery (Under Perpetual Stress, or United Parcel Service?) One end of the prop box was totally torn away and open. Yikes! I pulled the newspaper out of the end of the box and it looks like everything is intact. I will wait until I get it to the airport before opening the box to inspect the prop further.
Photos:
Here is a photo of the prop and hub boxes, caution clearly marked!
Here is the damaged end of the prop box as delivered. Way to go UPS!
[Top]
Copyright © 2003 - 2010 Mike Hoover. All rights reserved.