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.