Category Archives: Avionics

Aerials, Cowling, Dave Mills, Electrics, Instrument Panel, Propellor, Wiring

Monday 10th June 2019

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Music: Star Sailor and Turin Brakes

Dave came down to spend a day with me to see how the build is going so far and help me with fitting the prop hub and transponder aerial.

Forgot to attach the panel air vent ducting before I installed the panel. It’s a lot more fiddly i can tell you!
Now I’ve received the drive lugs I ordered from CFS Aero I can attach the prop extension to the drive plate. The bolts to attach the extension to the drive plate are 8mm and the bolts to attache the prop back plate are AN5. So metric and imperial in the same installation – how ridiculous!
The drive lugs are press fit and have a slight taper so the bolts are used to draw the lugs into the drive plate.
The bolts have been lightly tightened before torquing up to 24NM.
The mini slip ring control wires are adjusted so they hang just out the of the front of the prop extension.
Heat shrink tubing is added to each wire and the hub offered up to allow the control wires to be connected.
A heat gun is used to heat the heat shrink and the wires are pushed into the hollow shaft.
Some Duralac is added to the lugs that enter the hub to ease disassembly and the bolts tightened.
Time to check that I’ve got the measurements right for the prop extension so the engine cowlings are fixed in place.
A good fit with an acceptable gap, so shouldn’t rub in service. I’ll fit the blades closer to finishing the plane to save them getting damaged.
Next up is to install the transponder aerial. I’ve decided to mount it centrally between the main wheels. Still have to make up the coax for the radio and transponder but going to Air Expo on Thursday so will look to pick it up there.
Dave checking out the pilots seat before leaving for home.
So most of the main work has been completed so it’s time to start on the wiring. Not sure how long it’s going to take but need to make a tidy job of it and make sure that it’s easy to trace and maintain in the future.
Electrics, Instrument Panel, Panel, System

Thursday 6th June 2019

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Music: Dido, Easy 90’s

The aim for today was to finish adding the instruments to the panel, install the left and right footwell trims so I can install the instrument panel and get rid of the myriad of associated boxes and packaging!

The spinner of the Airmaster which would look even better on the front of the aircraft. The only problem is I don’t have all the components to fit it. I found out today that I’m missing the M8 Round-Neck Nut Set (of course I am!) They’re not supplied with the engine and not supplied by the propeller manufacturer! Quite amazing really. However a call to CFS Aero and a set are on the way to me for tomorrow.
The G5 has now been installed and one of the Skyviews.
The interior footwell panels are pre-drilled which makes it easier however they still need trimming and you need to make sure you know how they are fitted before starting to rivet. I’ve used some Clecos to secure the panel before riveting.
On the rear panels I’ve made them removable but these don’t need to be removable so I’m riveting them.
Of course one was easy to fit and the other took ages…
However all done now and looks quite neat. There’s carpet to cover the floor area which will make it look a little less utilitarian!
Now that’s done and the panel is complete it can be fitted.
It’s secured with 2 screws either side of the panel and 3 screws that screw into the centre console. It provides a very secure fit but may benefit from a couple of lightweight supports at the top of the panel.
The final panel, all the network cables have been fitted and the glare shield fitted temporarily and powered up using the backup batteries. The G5 backup battery has finally run out so I can’t switch it on which is a shame but overall I’m pleased with the result.
Carb Heat, Centre Console, Demister, Fuel System, Heater, Instrument Panel, Panel, Park Brake, Propellor, Tom Rose

Wednesday 5th June 2019

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Music: Roxy Music & Dire Straits

With all the prep to fit the centre console, today’s the day to fit it for the final time. All the control cable outers have been routed and cut, the connections worked out, the pipe runs decided on and checked. Now it’s just a case of carrying out the fit.

The fuel pipe from the selector to the tanks and engine need to be routed so they don’t kink and cut the supply whilst also being kept away from anything that may chaff them.
This shows the support bracket for the park brake cable. It works well.
The outer cables are wire locked to the adjusters so they can’t move once fitted.
The demist control with the connector we made up. It looks a very good solution.
At last the centre console’s complete with all the controls fitted, cables run and fuel pipes fitted.
Having received the prop on Monday I can start to install the various bits. This is the mini slip ring available for Rotax 912ULS type 2 engines. It’s fitted to the rear of the gearbox.
and then secured in place with a rod hat runs through the hollow gearbox shaft. The control wires spiral round the rod…
and exit the front of the engine ready for connection to the pitch motor wires in the spinner.
Once the slip ring is fitted the pick up bushes are installed. The bushes need run centrally on the slip ring. That’s all for the prop today, more tomorrow.
Moving on to the panel again. I will fit as much as possible before fitting to the aircraft as it’s a lot easier than fitting the components when the instrument panel has been fitted to the aircraft.
I’m not sure what Tom is doing here? Perhaps he’s going to start to sing? Captions please! He’s going home today so I’m solo again tomorrow!
Electrics, Instrument Panel, Panel, Propellor, Wiring

Monday 3rd June 2019

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Music: Röyksopp

Good news – Today I’m expecting delivery of the Airmaster prop that was ordered in February. So I had brought back the switches and circuit breakers and thought that whilst waiting I would wire them up.

Each circuit breaker is linked to one or more switches depending on the circuit design by making a connecting wire with 22 or 18 AWG wire with a couple of crimped female spade connectors.
The Aveo air vents were next and are secured by screwing the front and back components together.
At last! I have finally received the Airmaster prop. On first inspection the hub and spinner box looked fine and undamaged and the inside…
looks good too…
However the box with the blades in had quite a substantial gash in the front.
Luckily, although the cut went through both the outer and inner boxes, whatever caused it never hit the blades – Phew!
One of the carbon fibre blades, looks very swish.
Carb Heat, Centre Console, Chris Mills, Heater, Instrument Panel, Panel, Park Brake, System

Thursday 30th May 2019

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Music: Fleetwood Mac

A couple of jobs to focus on today. The first is to fit the circuit breakers and second is to start the fitment of the centre console that includes the control cables for Carb Heat, Park Brake, Cabin Heater, Demist and fuel pipes to the selector and tank lines.

I’ve printed labels using an electronic printer so I can easily identify the circuit breakers and switches once fitted.
Unlike the switches that have a hex nut and can be tightened with a spanner the circuit breakers have a knurled ring that is difficult to grip. I found the best way was to adjust some mole grips so they gripped the ring firmly that allowed me to turn the the ring a quarter of a turn at a time. It took some time but got the job done.
All the switches and circuit breakers are in now. Very pleased with the result, looks quite tidy!
The cables used to control various items have to be routed so they don’t snag. After a couple of trial fits the best route from the front of the panel to the control is to exit the centre console via a hole at the rear. Three cables will exit this way and the fourth which operates the park brake will exit the end of the console and loop back in. This makes sure that the control operates in the correct sense i.e. push is off and pull is on.
With the console in place I can test the routing again and once checked I can drill the other holes.
The carb heat cable is connected to the carb heat control using a radio control model clevis.
The centre console ready to be installed showing the park brake cable that loops round and back in connect to the park brake. Without doing this the park brake would operate incorrectly.
Chris has been helping me over the last couple of days but before he left I thought I’d install a screen and power it up. With the ADAHRS unit installed and wired it’s the first time that I’ve seen it myself – looks quite impressive!
Centre Console, Chris Mills, Instrument Panel, Internal Trim, Panel, Wing Lockers

Wednesday 29th May 2019

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Music: Elton John and Dire Straits

I received two pieces of good news today. The first was the dispatch notification of my Airmaster propellor which will be delivered on the 4th June. And the second was that the ignition switch that I ordered 5 days ago was arriving from Germany today! With Chris here for a couple of days he can give me a hand to do some of the jobs that I haven’t got round to like installing the rivnuts for the interior panels and fitting the wing locker seals. I continued preparing the panel for the instrument fit and working out how best to install the centre console.

Chris came down to visit and give me a hand with some outstanding items.
As I’ve decided to make the interior panels removable rather than rivet them in Chris’ first job is to install the rivnuts that will take the 3mm button head retaining screws.
Who says I’m a slave driver! A happy worker 🙂
After the rivnuts the next job for Chris is to fit the wing locker seals to ensure that they are waterproof. As the seals are not included in the kit!?!? I’ve brought some draft excluder that should do the job.
Good job done. The seals will ensure that any luggage is kept dry
I continued prepping the panel for the instruments. These aluminium ‘washers’ are to spread the load of the nuts when used to secure the instruments.
Autopilot, Electrics, Instrument Panel, Panel, Wiring

Tuesday 28th May 2019

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Music: Elton John and Turin Brakes

A few jobs today. Bond the switch plates to the panel, start populating the panel with switches, mark and drill the ignition switch hole, create the looms for the servos and solder to the respective servos.

The panel cutting is largely complete now with just some USB data and power ports to add and an ignition switch. I’ve sprayed it with the paint matched to the interior so it’s ready to have the switches added.
To ensure that the spacing was correct I marked and drilled the holes in a piece of 20 x 1mm aluminium and then drilled through the panel. This is now bonded to the back of the panel to give the switches a solid feel during operation.
I’ve riveted on a couple of spade tabs to the end of the strip just in case I need to use them for earthing.
The switches are installed and tightened with a 14mm ring spanner. Have to be careful here to line them up correctly and make sure that I don’t mark the paint!
I’m still awaiting the arrival of my ignition switch that’s on its way from Germany but luckily Ian had one that I could use to get the positioning right and drill the hole. Now they are in I can leave it to set before installing the circuit breakers.
Now onto creating the look for the autopilot servos. Dynon sells a servo wiring kit with 20′ of multicoloured wire of the correct gauge, it includes 2 female and 1 male D9 connector. There’s ample wire to make 2 looms from it so I’ve cut it in half and bundled the wires together in readiness for soldering to the servos and terminating with a female D9.
There’s a few things that’s important to remember when soldering;
1) Match the colours.
2) Make sure you slide on the heat shrink tubing before you start soldering.
3) Mark each end of the loom so you know what wires you’re working with.
Soldered and protected. The final bit is to slide another piece of heat shrink one the bundle to keep it all together and…
protect the loom with some conduit. I’ve decided to use split conduit from the servo to the throttle quadrant and then I’ll use poly sleeving from there to the connector block.
One of the things that I’m trying to do here is to keep everything neat and tidy for easier maintenance in the future if needed.
Instrument Panel, Panel

Friday 24th May 2019

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Music: Easy 80’s

After cutting the holes for the switches, circuit breakers and panels the holes for the retaining screws can be drilled and the panel painted in readiness for the avionics to be fitted.

Most of the instruments sit on top of the panel but the prop controller is fitted from behind so it’s a little more difficult to drill the holes correctly.
Once all the holes for the instruments and screws have been drilled the panel is sanded down with 600 grit wet & dry and then is can be primed with plastic primer.
The rear of the panel showing the strengthening that I’ve installed.
Pleased with the panel so far. Just the ignition switch to fit and a couple of top coats to match tie interior and then I can start installing the switches, circuit breakers and instruments and then start the wiring.
Instrument Panel, Panel

Thursday 23rd May 2019

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Music: JT and the Clouds and Daily Mix

Today was a little frustrating with news that the ignition switch wouldn’t be delivered until August! Grrr…

Well the day was dominated by checking up on another vital component, the ignition switch. After placing the order with a reputable aviation company I was told there would be a delay as they were out of stock (despite their system saying that they had them in stock). They advised that I would receive the switch on the 22nd May which I agreed to. As I hadn’t heard anything from the company I checked with them on Wednesday. They said ‘don’t worry sir we’ll drop you a line and let you know today’. Well that was yesterday and nothing! I phone them today and they said ‘don’t worry sir we’ll drop you a line and let you know today’. Surprisingly I said No! give me a call as soon as you have checked. 20 mins later and the voice on the other end said ‘It’s not good news sir – expected delivery is now August!’
I do find it amazing that customer service doesn’t seem to feature at all in some companies operation and they just don’t keep customers updated with any delays. I won’t name the company as it’s happened more than once during this project with different suppliers.
2 hours later and I found another supplier. It’s been despatched within minutes of placing the order and it’s on its way from Germany with delivery due in a couple of day.
With all the holes I’ve cut in the panel it needs a bit of support! I had a think and believe this to be the best solution. I’ve cut a couple of pieces of 25mm aluminium angle and drilled loads of holes in it so it will ‘key’ onto the structure better.
I’ve also drilled some holes in the side of the support braces so I can use them to secure wires behind the panel with some cable ties. The angle is secured in place with glass fibre cloth.
A layer of glass fibre is set first that the support will sit on and then another layer of glass fibre is set over the top. This should provide a very strong bond.
This is how it will look once finished. Another layer of glass fibre needs to be laid over the outer supports to finish off but I’ve run out of time today due to the switch fiasco so will finish of tomorrow!
Instrument Panel, Panel

Wednesday 22nd May 2019

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Music: ELO and Elton John

The trim indicators and manual prop switch holes need to be cut today. I’ve also ordered the paint for the panel that matches the interior panels, it should be ready tomorrow morning so I’ll paint it once I’ve cut the rest of the holes in the panel.

Same procedure to cut the holes for the trim indicators. Finishing the holes with a file.
A trial fit of the indicators. Looks about right.
The panel and centre console installed to trial cable runs. Looks quite good even if i say so myself! With all the cut outs I need to strengthen the panels I’ll attach some aluminium angle behind the panel with fibreglass.
The final control to be installed is the manual switch for the prop. The cut out is made in the same way but I’ve decided to install this control in the centre console just in front of the throttle.