Completed the prop and spinner

Went flying with Jared, Wes, and Scott. Got some nice pics of Wes’s RV-7A in fingertip formation on the way to KLZU for dinner Thursday evening.

img_4758

 

Jared came over on Friday and helped me hang the prop. Leveraged my specialization in brute force and stupidity to turn a one hour job into a five hour epic involving a three hour journey to and from Aircraft Spruce for a new prop wrench. All’s well that ends well.

img_4776

 

Safety-wired  the prop mounting bolts.

img_4780

 

Mounted and drilled the spinner, spinner plate and forward bulkhead. Used the neodymium magnets and plastic washers that came with the kit to locate the holes in the forward bulkhead.

 

Installed nutplates into the bulkhead and re-mounted it. Torqued and safety-wired the bolts.

 

Fabricated and installed the gap fillers. Clamped a couple of wooden boards to the prop blade as a lever to rotate the blades (change their pitch) in order to check the clearance of the spinner and gap filler. I used a sanding drum in an electric drill to make minor adjustments to the spinner and gap fillers. Then riveted the gap filler to the spinner plate.

 

Reinstalled the spinner.

 

Today’s Time (hours): 10.0
Finish kit (hours): 241.0
Total Time (hours): 975.0

Prop prep, cabin heat, and sniffle tube

Uncrated the prop.

img_4732

Match drilled and clecoed the spinner plate doubler to the spinner plate.  Marked and cut out the center of the spinner plate with a skill saw. I cleaned it up with files, and a bit of emory cloth. I scuffed and primed the plate and the doubler then riveted them together. I attached the spinner plate assembly to the back of prop and re-torqued the bolts. The prop is now ready to be mounted to the engine.

Installed the heater muffs and associated SCAT hoses.

Fabricated and installed the sniffle tube.

img_4746

Today’s Time (hours): 8.0
Finish kit (hours): 231.0
Total Time (hours): 965.0

Completed engine wiring, plumbing, oil cooler

 

Assembled the oil cooler inlet and tray. Trimmed, deburred, and primed all the parts and then riveted them together. Glued the seals in place and sealed all the gaps with RTV. Installed the AN fittings into the oil cooler. Bolted the tray to the firewall and engine mount. Then mounted the air cooler and inlet. Connected the feed and return lines to the oil cooler.

 

Wired the EGT sensors, CHT Sensors, and Fuel flow sensor.

 

Created a hose for the manifold pressure sensor using Aeroquip AQP hose and reusable connectors. Ran that hose to the sensor block from the primer port in the #3 cylinder head. Also ran a line from the sensor block to the MAP port on the right PMag. I the manifold pressure, fuel pressure, oil pressure, and oil temperature sensors using crimp on, fully insulated, quick disconnect terminals.

 

 

Today’s Time (hours): 14.0
Finish kit (hours): 223.0
Total Time (hours): 957.0

 

Installed the fuel injection servo and exhaust system

Installed the fuel injection servo. A gasket, four nuts, and two fuel lines. pretty straightforward.

 

Installed the exhaust system. Slightly less straightforward than the fuel servo but not too bad. 

 

 

Today’s Time (hours): 5.0
Finish kit (hours): 209.0
Total Time (hours): 943.0

 

More engine stuff

I wired up the ammeter. I picked up a couple of inline fuses that had mounting holes. I attached them to the engine mount with an adel clamp.

 

img_4695

 

I fabricated a mount for the Garmin GA 27 GPS antenna by modifying the suction cup mount that came with the antenna. I cut it to match the profile of the antenna, bent the mounting tab to a right angle and cut it shorter. I drilled a hole for the mounting screw and viola.

img_4696

 

I wired up the left magneto.

img_4698

 

I installed the fuel line form the firewall to the fuel pump.

img_4699

 

I cut the right angle hose segment and installed the breather tube.

img_4700

 

I installed the line to the oil pressure sensor.

img_4701

 

I began terminating the oil, fuel, and manifold pressure sensor wires but realized that I didn’t have any fully insulate quick disconnect terminals. So put in my daily Aircraft Spruce order.

img_4702

 

I wired up the right PMag.

img_4703

 

Attached the upper and lower oil cooler lines.

 

 

Today’s Time (hours): 7.0
Finish kit (hours): 204.0
Total Time (hours): 938.0

 

Engine install continues

Eeked out a few hours of building this week.

Installed the fuel overflow tube.

img_4680

 

Installed the dipstick tube and lock wired it in place.

img_4682

 

I ordered a tach cover from Vans and this is what showed up. It has no means to lock wire it. I’m going to replace it with one from Spruce.

61057956656__0b035d0f-1f5c-4d94-9dd9-309a20e637f7

 

Installed the oil temperature sensor.

img_4685

 

Installed the alternator.

img_4687

 

Installed the cylinder head temperature sensors.

 

Today’s Time (hours): 4.0
Finish kit (hours): 197.0
Total Time (hours): 931.0

 

Installed prop governor, fuel flow sensor, and sniffle valve

Installed the prop governor. I wasn’t sure what hardware to use. The plans said to refer to the engine/governor installation instructions. The Hartzell instructions said to refer to the engine manufacturer’s instructions. The Lycoming instructions that came with the engine were mute on the topic. I was able to find an illustrated parts catalogue for the engine on Lycoming’s web site. It showed a washer, a star washer and a plain nut. Now I need to figure out where Lycoming keeps its torque values.

img_4670

 

I installed the fuel flow sensor and the fuel lines from the fuel pump and to the fuel injection servo.

img_4672

 

I installed the sniffle valve. This seemed like it was going to be straightforward. Remove the plug; install the valve. What I didn’t take into account was that the intake manifold was full of preservative oil. So now my nose gear and tire are well lubricated and in no danger of corroding.

img_4673

 

Today’s Time (hours): 2.0
Finish kit (hours): 193.0
Total Time (hours): 927.0