Wiring Continues

Haven’t posted in a while but making steady progress.

Made a wiring harness for the TO/GA switch.

Wired up the canopy harness.

Relocated the GAD 27, GAD 29, and GEA 24.

Made up two of the four connectors for the GEA 24. Had to re-order the thermocouple wire for the EGT and CHT connections. I accidentally ordered solid wire instead of stranded. Connecting the engine to the airframe, there’s enough motion in those wires that I wasn’t comfortable using the solid wire. It probably would take long for it to work harden and break.

SO. MANY. WIRES!!!

So glad i borrowed Jared’s engine stand rotisserie. I can’t imagine doing this with the airframe upright.

Today’s Time (hours):	8.0
Finish Kit (hours):	128.0
Total Time (hours):	858.0

Began work on Common Fuselage Harness (Section 55)

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Ran the right side harness from the aft fuselage bulkhead all the way to the panel and pulled the wing portion of the harness out through the side skin and fastened the ground wires.

The harness from Van’s was designed for the Garmin GMU 22 magnetometer. Garmin has since come out with the GMU 11 and that is what was included in my avionics package. The GMU 11 broadcasts heading information on the CAN bus rather than the RS-232/RS-485 point-to-point topology. This requires some modifications to the harness. I teased out the 2-conductor shielded cable that carries the CAN bus from the autopilot servos in the tail to the instrument panel from the harness and rerouted it to the left wing where the GMU 11 is mounted. I will repurpose a couple of connector pins in the wing harness for this and make up a harness to wire the GMU 11 to the wing harness connector (P403). I can then reuse one of the the 2-conductor shielded cables from the P403 connector to the panel to bring the CAN bus from the left wing to the panel. I’ll use the four conductor cable to bring power, e-bus power, and ground to the GMU 11 from the power bus and ground block. All in all this is a huge pain in the ass and required a lot of head scratching. I wish Van’s kept up with the state of the Garmin offerings. Even if they can’t update the harness, at least cover it in the instructions.

I managed to get all of th snap bushings in place. I added a few tie wraps as well. I’m thinking I’d like the harness to be more secure between the spar and the aft fuselage bulkhead. Looks like there’s opportunity for the elevator push tubes to rub the harness. I’ll work on that once I’ve got all the wires run.

I haven’t run the control stick harness through the cover ribs yet. Looks like the holes require some filing to fit the connectors through. Thanks again Van’s. Perhaps the plans could have called this out prior to installing the ribs. Very tight spaces to work in. That will be tomorrow’s project.

Today’s Time (hours):	3.0
Options and Miscellanea Time (hours):	41.0
Total Time (hours):	730.0

Started mounting avionics

Made some trial panels from plastic. I’ll use these to lay out the panel and make sure everything fits before I start cutting metal. I’f I do this properly and everything works out, I should be able to use these as templates to lay out the actual metal panels.

Temporarily mounted the GAD27 (ARINC), GAD29 (electrical device controller), and GEA 24 engine indication system. I mounted the GEA 24 directly to the sub panel. I made a stand-off mount for the GAD 27 using some aluminum sheet and some aluminum tubing. This let me “stack” the two boxes fore and aft. This was the same approach that Jared took in his plane. So I can’t claim credit. I also mounted the TCW integrated backup battery system. I fit the boxes, drilled the sub panel, and attached the boxes with temporary hardware I had lying around. I’ll get the proper hardware this week.

I fabricate a doubler to mount the WaaS GPS antenna. I cut a piece of aluminum to sive, laid out the holes for the antenna and rivets. I match drilled the empennage top skin to the doubler. I dimpled the doubler, riveted nut plates to it, and primed with SEM rattle can. I dimpled the top skin with the pop rivet dimple dies. I riveted the doubler to the inside of the skin and screwed the antenna in place with the supplied hardware.

Started fitting the radio stack. I used a digital level and shimmed up the front of the radios so that the were perpendicular to the panel. Determined that I need to enlarge the center opening in the sub panel in order to accommodate the radios without blocking the canopy release. Even then, everything barely fits.

I picked up a vibratory cutter and a flush cutting blade. I’ll use this to cut the sub panel tomorrow.

Today’s Time (hours):	6.0
Options and Miscellanea Time (hours):	7.0
Total Time (hours):	682.5

Bottom Skins Complete

Received the new quick-disconnect terminals and replaced the bad ones. Then I final-installed the pitot tube into the wing and hooked up the plumbing and the electrical. Had to uninstall and reinstall the aileron push tube so that I could get my hands in there.

Reinstalled and torqued the aileron push tube in the right wing and installed the aileron trim. Getting those springs on is tricky. I also took the time to bend the actuator arm aft a bit. I just saw a picture on VAF where someone’s springs had almost worn completely through the push tube. Plenty of clearance now. No rubbing.

Riveted the nut plates for the right wing inboard fairings and inspections plates.

Almost done! Just the wingtips left to do.

Today’s Time (hours):	2.0
Wing Time (hours):	285.0
Total Time (hours):	437.0

Started riveting the bottom skins

The rest of my avionics order showed up this morning. I also received the GMU 22 mounting kit from Van’s. Apparently they don’t make one for the GMU 11 (which is what I bought). So I took a chance and ordered the one for the GMU 22 thinking I could cannibalize it and create something for the GMU 11. As it turns out, all I needed to do was to match drill four holes to the base of the GMU 11. So I drilled the holes, cut the top half of the mount per the plans, deburred and primed everything, riveted it together, and screwed on the GMU 11. Bayum!

Remy helped me rivet the inboard bottom skin to the right wing. It was challenging to reach the rivets along the aft spar. Remy and I took turns bucking and shooting. Nonetheless, tomorrow will definitely be an Advil day. I clecoed the outboard skin in place. That can be tomorrow’s challenge.

Today’s Time (hours):	3.0
Wing Time (hours):	270.0
Total Time (hours):	422.0

Cut pitot and added connectors

Just got back from Oshkosh this afternoon. And couldn’t resist heading down to the shop to get something done. Amazing trip with up and back with Jared in his RV-14. Got to meet up with Wes and Joy and met Craig and his son. This was my first time at AirVenture. It was simply amazing but I’m exhausted. I think we averaged 7 or 8 miles walking each day. The airshows were amazing. Especially the night show. Best fireworks and pyrotechnics I’ve ever seen.

I cut the aluminum tubes from the pitot tube assembly using a tubing cutter so that they would clear the aileron push tube when installed in the wing. I added the AN hardware, flared the tubes, and screwed on the adapters. Then screwed the push-to-connect elbows on to the NPT side of the adapters with a bit of Loctite thread sealer. All ready to install.

Today’s Time (hours):	1.0
Wing Time (hours):	267.0
Total Time (hours):	419.0

Installed Autopilot Roll Servo

Drilled and tapped the aluminum tubes to accept the 1/4 threads of the rod end bearings. Assembled the AP pushrods. Fabricated the spacer for the roll servo.

Installed the roll servo into the right wing.

Today’s Time (hours):	2.0
Wing Time (hours):	266.0
Total Time (hours):	418.0

Received fuselage kit and avionics

Very busy inventorying all the new parts. I’ll complete the wings before I get started on the fuselage but want to get it all inventoried.

I also received my avionics order. Going with a Garmin G3X Touch system with a GTN 625 Navigator, a G5 for backup PFD, and a 200B com radio. I bought it from Gulf Coast Avionics.

Today’s Time (hours):	4.0
Wing Time (hours):	260.0
Total Time (hours):	412.0