Category Archives: Fuselage

Autopilot, Electrics, General, Instrument Panel, Sensors, System, Wiring

Monday 17th June 2019

17/06/2019 Trevor Mills 2 Comments

Music: Fleetwood Mac – Saw them in concert at Wembley last night. A little treat from Karen – Absolutely fantastic!

The wiring continues, after each circuit is wired up a check to see if it’s working as expected. All good so far!

As mentioned previously I need to protect the SkyView from a surge from the Amp Shunt so I’ve purchased some 1 amp inline fuses. They are very small…

… and make for a very neat protection solution when positioned inline.

With all the wires ‘under the bonnet’ it’s difficult to make it all tidy…

…but I layout all wire first to see where best to route them before trimming to correct length and terminating. All these will need to be secured too with stand-offs as required.

The servo looms are next. I’ve installed the looms as far as the cockpit and now need to terminate each wire and make up the connector. It requires crimping the pins on each wire with a 4 way crimper.

After crimping they are inserted into the D9 block…

…and the backshell is added. Fairly straightforward but you have to make sure that the crimps are secure. There are two of these, one for roll and one for pitch. Once made up they are plugged onto the SkyView network hub.

Next up is to finish off the engine sensor connections. The correct pinout from the D37 connector is identified and the wire routed as described before trimming to the correct length and terminating. In this case a uninsulated spade connector that slips over the sensor connector. This is the LH CHT sensor…

A quick check that everything is working. The CHTs, EGTs, Oil Temp, Fuel pressure, Oil pressure, Voltmeter, Ammeter and autopilot have now been completed and work as expected.

Electrics, Instrument Panel, Sensors, Sensors, System, Wiring

Friday 14th June 2019

14/06/2019 Trevor Mills Leave a comment

Music: Take That

I decided to visit Air Expo at Booker yesterday but I can honestly say the show was a complete waste of my time. It was raining all day and a lot of the exhibitors had scaled down their stalls and some hadn’t turned up at all! I did buy a Sky Echo II there so I’ll see how that works when I finally get the plane flying.

The aim for today was to continue the wiring and connect a few of the sensors.

The EMS loom has a D37 that connects to all the various sensors around the aircraft. It’s good to check the pin out with a multimeter before connecting to any of the sensors.

*First up is the MAP sensor. The power and ground on this sensor can be shared with other sensors so I’ve broken out those pins to use for the the fuel pressure sensor.*

The system power load can be displayed on the SkyView by measuring the potential difference across a precise resistive load, in this case a Amp shunt. The wires connect to either side of the resister. To protect the SkyView from high currents a 1 amp fuse is connected inline which I’ve ordered and will be arriving Sunday so I’ll fit on Monday.

The landing light controller that I bought from the States is wired up to a 3 position switch. I’ve designed the lights to be steady, wig wag and strobe. Hopefully it’ll work as designed.

To get the light functions I need a 3 pole and 2 pole switch.

The fuel pressure sensor is next but will be done on Monday now as I’ve run out of time.

The HDX displaying in s ‘6 pack’ mode but you can see some of the sensors working correctly including the MAP, voltmeter and ammeter readings.

Electrics, Instrument Panel, Landing Lights, Lights, Panel, System, Wiring

Wednesday 12th June 2019

12/06/2019 Trevor Mills Leave a comment

Music: Ed Sheeran and Turin Brakes

Work continues on the wiring today (and no doubt for a few days more but got quite a lot done today having completed the Master, Fuel Pump, HDX 1, & 2, G5 and Radio circuits.

This is the loom for just one of the SkyView HDX screens. It looks intimidating on first looks but they all do something and you just have to work out where they go!

The difficult bit was designing the electrical circuit to power all the devices. As I’d fitted the circuit breakers and switches and fitted the interconnecting wires it makes it quite easy to complete the circuit.

so I’m starting to arrange the wire bundles in an orderly fashion as planned.

This is the Wig / Wag controller that I bought from the states to give better visibility whilst flying. It allows the landing lights to be steady, flash alternately or flash like a strobe. Just hope it works as promoted!

ADAHRS & GMU, Electrics, Instrument Panel, Panel, Primary Power, System, Wiring

Tuesday 11th June 2019

11/06/2019 Trevor Mills Leave a comment

Music: Röyksopp and Dido

It’s time to do the wiring. This is going to be long job as there are wires all over the place! There are some things that must be done to make sure that it’s maintainable in the future like labelling as it’s easy to lose track of where wires are going from and to and obviously it’s got to look neat and tidy. First thing is to look at suitable routings for the bundles and make sure they make ‘sense’ then start laying them out. This is one of those jobs that you just have to keep going at and eventually it’s finished!

First up is to protect from reverse currents when the master switch is turned off. This is accomplished by placing a diode across the positive and negative posts on the battery contacter.

It looks a quite simple but it gets the job done.

One of the easy jobs is to run all the ‘earths’ back to the earthing block. After terminating each wire with a insulated female connector a label is attached to the lead. These are just printed off a electronic dymo babbling machine and seem to be suitable for the job.

Once the earth is connected, a quick check of the circuit logic and then I can temporarily power up the circuit.

Whilst the screen is powered up on main power I thought I’d update the system software to the latest version. The software has a boot loader that updates all the other attached devices like the autopilot and knob panel.

Last job today was to run the G5 to GMU11 loom in and secure in place.

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

Monday 10th June 2019

10/06/2019 Trevor Mills Leave a comment

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

06/06/2019 Trevor Mills Leave a comment

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

05/06/2019 Trevor Mills Leave a comment

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!

Carb Heat, Centre Console, Demister, Heater, Park Brake, Tom Rose

Tuesday 4th June 2019

04/06/2019 Trevor Mills Leave a comment

Music: Easy 80’s

Tom came down to stay for a couple of days and give me a hand. Luckily he bought some tools with him from the land of the giants!

Today we were concentrating on fitting the centre console, ensuring that all the control operate smoothly for the carb heat, cabin heater and demister. The park brake needed some special attention as it needed to operate with push on and pull off. This required the cable to exit the front of the console and loop back in. This would make it operate in the correct source but there would be about 100mm of unsupported cable which would bend and it’s unlikely to operate correctly. The other connection that would need a bit of thought would be the connection to the demister as it had a protrusion to connect to and not a hole like the other controls.

Tom always comes equipped for the job. I think he was was going to work on a JCB not a Bristell!

The demist, heater and carb heat control cables routing over the equipment tray.

A test of the parking brake proves that the cable will bend and fail to operate without additional support. Inside the centre console there are quite a few other cables and they need to be positioned so they don’t interfere with each other. In addition to this the fuel pipes have to fitted to the fuel selector.

Our solution is to prevent the outer cable from bending piece of aluminium tube and then making a bracket to support it in the console.

This looks to be a good solution to the problem. A final wire lock ensures that the cable doesn’t move, so full movement is realised.

A radio control clevis is used to connect to the cable. Time will tell whether this is a reliable solution.

…carb heat controls are very straightforward but the outer cables still need to be fully secured otherwise the whole cable will move and fail to operate the attached item.

The demist attachment required a different solution and after some thought we came up with the idea of using a piece of 2mm aluminium to extend the RC clevis.

The final solution which will do the job. The only thing to do is fit it!

So Tom launched into action! It’s all a bit difficult to get to.

With two out of the three fuel pipes connected and all the wires and cables routed as require we can call it a day. Tomorrow sees the final fit and we can move on to the prep for fitting the panel and prop.

Lovely sky as we exited the workshop. Need to get the build finished so we can go fly in skies like these!

Electrics, Instrument Panel, Panel, Propellor, Wiring

Monday 3rd June 2019

03/06/2019 Trevor Mills Leave a comment

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…

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

30/05/2019 Trevor Mills Leave a comment

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.