More cowl baffles, wiring, control cables, etc etc

Since last post have been jumping around a bit.  Still waiting on some re-fit of fuel and oil lines to finish up install of fuel servo and snorkel.  Installed control cables to panel, completed the prop control cable - waiting to finish the throttle/mixture when servo install done.  I've gotten all the wires through firewall, cleaned up wiring under the panel/subpanel, and connected the sensors forward of the firewall, and the top spark plugs.   I'm using Deutsch DTM connectors and service loops for all the sensors.

I had to do some inventive bracket fabrication to stabilize the manifold pressure hose.

Also got the manifold pressure hose connected to PMAG.  And more little stuff.  FWF is starting to look more complete.  Still lots to do of course....

Upper plugs 1 and 3:

Bracket for manifold pressure line and sensor wiring right side:

Battery / alternator cables, ANL fuses, ammeter shunt, sensor connections on left side. 

Left side firewall pass-through.  Sealed it because I can't add any more wires here.  I did put a couple of spares in place for any future needs.

 Control cables in place:

Cleaned up wiring:

Prop governor control:

Work continues on cowl baffles, partially installed remote air filter kit, odds & ends

I completed installing the cowl baffles around the engine/cylinders today.   Also did final fitting of nose wheel fairing after laying up some extra layers of fiberglass cloth in the area where the brackets will be attached - I'll also use flox to perfectly fit the brackets to the fairings.

The remote oil filter has two advantages over standard location: first, it's much easier to change the filter without making a huge mess and second, lower oil temps according to Airwolf (company that makes the remote filter kit) and anecdotal experience as well.

I test fit the snorkel today and having trouble getting it to fit due to interference with the induction tube for the #2 cylinder intake pipe.   I'll call the mothership tomorrow for advice on this.


Remote oil filter adapter with vernatherm and oil temp sensor installed:

Oil filter bracket on firewall.  I will be ordering lines from the adapter to the bracket.

Adapter "in situ":

Baffles in progress:

Installed on engine:

Can't get snorkel properly fit due to interference with cylinder intake.   This is with the air filter frame removed - can't get close to putting it and snorkel together with the frame properly seated.

Panel nearly done, starting work on cowl baffles

I spent most of the time since last post finishing up wiring for panel, installing panel screens (G3X and G5), installed transponder antenna, etc.   Finished up install on ELT.

Started work on the cowl baffles.  I'm painting them with dupli-color red that's very close to the Lycoming Thunderbolt crankcase.

Continued work on avionics, odds&ends

Panel is slowing coming together - I'm routing wires, installing all the boxes and panel displays, items like the standby alternator regulator, CO detector.  Lots of effort to make wiring neat and protect it from possible chafing.

Installed the ELT except for the audio module which goes in the VS - I'll do that when VS is back in my shop and I can drill a couple of required holes.   The DIN connector on the ELT is a bit of a pain: about two years ago I crimped female "micro molex" connectors on the wires: these are supposed to fit on the pins on the DIN connector, but I couldn't get them to fit.  What does fit nicely is "high density" female d-sub pins, so I used these and very carefully assembled the DIN connector, using RTV and heat shrink to reduce risk of pulling wires loose.

Working (mostly) on avionics: Panel now IN THE AIRPLANE

Since last post, working on a few odds and ends, like installing the fuel flow transducer on the engine, and finishing some items related to engine installation.

Mostly I've been working on avionics - mounting the posts for the ground block, terminating all the grounds for the block, adding wires to the harness for items like my baggage area lighting, ground and "sense" (data) wire for the heated pitot, the molex connector that will connect to the canopy wiring harness, terminating coax cable for various antennas, etc.  Also spent quite a bit of time tidying up wire in the airplane to make room for the circuit breaker panel and make sure wires and hoses stay clear of controls, are protected from chafing etc.   Routed hoses for AOA and pitot through fuselage.

I also had to drill holes in the panel for a couple of items that were added late: indicator light for the standby alternator, hole for a switch to change the under-glareshield lighting from red to white, and enlarge the hole for the canopy ejection handle to make it large enough for the handle to fit.  I made some harnesses for items like the standby alternator regulator, indicator light for standby alternator, and the molex connector mentioned before - each of these integrated where possible into the main harness by threading wires into the harness lacing, and using strategically placed cable ties.

I also had to cut the outside air temp probe wire to route it out through the fuselage, and I made a connector using DTM type connector to connect it back in the panel area. 
After getting the harness to a point of readiness where it was time to put in the airplane, and because my wife wants her dining room table back, tonight I installed the panel. Went perfectly and I'm well down the road of getting all the boxes plugged in.  Back shells for GTN650 and audio panel are in and test fit looks good.

It's starting to feel like I'll be flying this thing soon.....


Grounding block with terminated ground wires - some spares too for future use.

Fuel flow transducer:

Fuselage wiring tidy-up:

Panel installed:

Fuse block for a few items that weren't covered by the circuit breaker panel (Baggage area lighting, standby alternator wire for indicator light, canopy lighting, etc.

Wiring harness behind panel still a mess but will be easy to tidy up:

Test fit of center stack, looks great if I do say so myself...

Engine accessories, antennas

I've gotten into a mode of back and forth with various tasks.  Since hanging the engine I've attached a number of accessories like prop governor, alternator and associated adel clamps for wiring to starter, alternator.   Also various hoses for oil and fuel, and the fuel flow transducer.

Also bit the bullet and drilled holes in the top of the airplane for the Garmin GA-35 antenna that will connect to the GTN-650 IFR navigator.  I first made a doubler / backplate with nutplates to anchor the screws that go through the antenna, then used the same measurements to drill the holes in top of airplane, on the right side, aft of baggage bulkhead.   No big deal really.   I had to wait until this week to get the right connectors for both ends of the cables for GA-35: it's a different type of connector than other antennas.

Also installed the two com antennas on the belly, and cleaned up wiring in the tunnel in preparation for installing my main panel and harness.

Big day today, progress continues on all fronts...

Today my EAA tech counselor (and RV expert) Vic Syracuse visited for engine hanging.  I'd like to say I did the work, but mostly I just assisted and held tools.   We got all the various ports installed on the back of the engine, and safety mounted engine on the airplane.

Since last post I've also: 

• placed various wiring for avionics and routed wires for GTN 650 antenna and baggage light
• started process of fitting nosewheel fairing
• mounted items on firewall in preparation for engine hanging
• finalized safety wiring of main wheel fairing brackets
• prepped parts for installation of various engine accessories.

Various fittings ready to install:

Alignment aids for nose wheel fairing

Firewall mounted items: master/starter relays, manifold for oil/fuel pressure, manifold pressure sensor, etc:

Engine installation in process (Vic Syracuse in blue shirt):

FINISHED!!!