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  #441  
Old 09-03-2018, 12:39 PM
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N941WR N941WR is offline
 
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Axel,

Your panel looks great! I can't wait to see a picture of it all lit up!

Quote:
Originally Posted by Snowflake View Post
Those "nuts" look like inserts used in injection molding... They give you a solid brass thread when molded into a plastic body. The knurling on the outside is to give good security in the plastic. Interesting application to use them as nuts to hold an instrument in place... The knurling is good for finger tightening too. Do they have a nylon insert or something for thread locking?
Those nuts are similar to what you describe but are designed for finger tight applications.

The back case in the EIC32 in Axel's panel is printed on (the front is injection molded) and we were afraid someone would over torque standard nuts and pull the threaded studs out of the plastic. That hasn't happened with these brass nuts, yet. A dab of Loctite can be used, but I'm not sure if it is necessary.
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  #442  
Old 09-04-2018, 05:08 PM
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daddyman daddyman is offline
 
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Location: Fredericksburg, Virginia
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Default Wow, what a panel

Quote:
Originally Posted by AX-O View Post
CRYING DOES NOT HELP!

Since I am down doing changes and not flying, time to also get the avionic software upgraded and add ADS-B installed.

The first avionics upgrade is the new EICommander. A little bit of cleaning up on the existing panel hole, some lite sanding on the 3D printed instrument case and perfect fit. I lucked out on this one. There is about 1/16 inch between the face of the EICommander and the canopy bow. This will allow control of both PMAGs and provide feedback. Straight forward installation. It did come with a nut that I have never used before. I finger-tighten them. Installation should take no more than 2 hours. I got about 45 min in yesterday and all the wires are set up on the FWF side and ran into the aircraft.











Axel,
I have panel envy.
Daddyman
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  #443  
Old 11-28-2018, 11:16 PM
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AX-O AX-O is offline
 
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Location: SoCal
Posts: 2,278
Default Dilemma 2.0

Well this has been ruff. Plane has been down since Jul. I am getting close but at this point, the introduction of Dilemma 2.0.

Since I originally made the firewall without the cut out, i had to overcome some limitations with the metal. That is why you will see a few dots of sealant on the firewall. Although the holes ended up in front of a bracket when folded over and were no impact, i still wanted to make sure they where covered up.

The firewall is sharp. If you look at it wrong, it will come out and bite you. In the below pic I did not even know i got a cut.



Pics of the completed firewall below. In the process I had to get rid off the fitting used for the Man Press on the firewall. I will be finishing that this weekend. I had to remove the battery from the firewall and I was still not able to get the pneumatic rivet gun in there.







After the front and aft plugs inside the crank were removed/replaced per Lycoming Service Instruction 1435, I proceeded to install the prop governor (PCU5000) and bracket.

I purchased a bracket from Show Planes and hacked it to pieces to fit my set up. I found an elevator trim cable around the shop and used that for trial fit. The cable throw was 2 inches and matched the throw and bulkhead attachment dimensions of the throttle and mixture.





I got the governor pad from a teammate that no longer needed it. I was also able to get her old oil line. The governor pad fit well and the studs were already long enough so that was pretty easy. The difficult part was making that steel line fit as it was designed for a different motor. I gave up at one point and went in search for a new one. That was abruptly stopped as the line was approx $650 new. With the new found motivation, I was eventually able to make the line fit. Pics show aluminum fitting for trial fit. Final installation is steel per the Service Instruction. I had to cut away the baffle in front of the #1 cylinder and the matching location on the engine plenum.





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Axel
RV-4 fastback thread and Pics
VAF 2019 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weight out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk.
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  #444  
Old 11-29-2018, 09:51 PM
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gmcjetpilot gmcjetpilot is offline
 
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Got to chime in on prop gov oil line. That thing is very critical.
If it fails you loose all your oil. So make sure you:
  • Use new stainless steel line (hard line or flexiable line is an option)
  • Use steel fittings
  • Make sure it is well supported with adel clamps along it's length.
  • Make sure it is not rubbing and you have no nicks, rubs, scratches.... if they are minor you might blend them out, otherwise replace the line.

I have read a few accident reports and the aluminum line and fittings was an AD a few decades ago.
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  #445  
Old 11-29-2018, 10:45 PM
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AX-O AX-O is offline
 
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Quote:
Originally Posted by gmcjetpilot View Post
Got to chime in on prop gov oil line. That thing is very critical.
Thanks for the feedback. Per text on the previous post, the aluminum fitting was for trial fit only. A steel fitting has been installed.

This is a steel line that looks brand new. I used a tube bender to move the end of the line 1/2 inch closer to the fitting.
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Axel
RV-4 fastback thread and Pics
VAF 2019 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weight out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk.
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  #446  
Old 11-29-2018, 11:01 PM
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AX-O AX-O is offline
 
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Default Time management test.

While I was waiting on parts purchased, numerous projects started to happen in order not to stop progress on things that were going to happen any ways. Unfortunately that can be a double edge sword scenario.

- I decided to send the electronic displays off for some upgrades. So additional high speed serial ports were installed along with upgraded graphics and computer processors. They also got upgraded to display Synthetic Vision.

-A serial expander was purchased in order to install an ADSB in/out solution.

-The 430W was sent off for an upgrade to ADSB+.

-An ADSB unit was purchased.

Before I started the ADSB upgrade, I studied the manufacturer’s instructions and ended up making some schematics showing the connections. I sent those schematics to the electronic display manufacturer and got the ok. They told me it should work well and last a long time. I set off to do the work and spent about 7 or 8 days cutting avionic lasing string, pulling pins, making new wires, routing wire, reading diagrams, making sure the smoke remained in the boxes, putting everything back together then setting up the configuration on the displays and ADSB units.

Although the smoke remained in the boxes it became very apparent during configuration set up that something was not working correctly. The ADSB unit has 2 COMM channels. The RX and TX on each channel have to match in baud rate per design. The 430W is putting things out at 9800 baud rate. The ADSB unit is expecting 115200 baud rate. The transponder rate is also at 9800. So unfortunately I did not have enough channels to work with. In addition to those problems the electronic displays were not displaying the engine information.

The problem with the engine information not being displayed turned out to be an issue that if the EIS signal came into the serial expander, it would not just go through (or out) to the displays. Unfortunately, I was not told that when the original schematic was sent to the electronic display manufacturer for their blessing. So all that work had to be undone and the serial expander come out because I had to change the way the display ports needed to be wired/configured.

I also had to rewire the ADSB unit. After talking with the manufacturer, they told me that they had a fix for my problem and they would send me the harness for free. A few days later it was home. This harness takes input from the transponder and the 430W, combines it and then feeds it into the ADSB unit. The Folks at UAVIONIX were very nice, professional and quick. Fast forward a few months and the ADSB info seems to be talking to each other. I installed an ADSB antenna on the fuse at the cowl exit. It is close to the transponder antenna so I will have to see if there are any issues. I am hoping the antenna can aid the airflow under the cowl exit. will post pic of antenna later. Pics below of ADSB harness. If you have a 430W and a 327 transponder, you will need this.





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Axel
RV-4 fastback thread and Pics
VAF 2019 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weight out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk.
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  #447  
Old 11-29-2018, 11:33 PM
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AX-O AX-O is offline
 
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I sent out my throttle quadrant to Dayton Murdock at DJM Manufacturing so he could use some of my old parts (they were matched drilled to the fuselage for mounting) and add the Prop lever.

I also asked him to implement his new dual lock system were you can lock down the prop and mixture control levers and unlock/lock the throttle independently. The -8 I have been flying was a pain to fly during formation shows due to the prop lever and throttle lever not liking each other. Now I don't have to worry about that.

He duplicated my AR-15 handle and even added a push to talk to it. He did an amazing job.

The new quadrant is an inch wider so that presented some issues. I had to make a new side panel and find a way to mount the ELT remote control unit.

I also had to figure out how to run the new cable to the prop control. I ended up using the mixture cable hole on the bulkhead and then drilled a new hole for the mixture in an existing AN3 hole. The geometry worked out well.

The last thing around that area was that the paint was coming of in a few places due to paint reaction while I originally painted the cockpit. So I removed some of it and wrapped the area with Dinoc.

old build picture of the throttle area


New throttle quadrant, notice the 2 different locks










Then I had to figure out how to mount the ELT remote control and how to get clearance enough so I could mount the throttle quadrant back on the fuse.




Then made the new panel/cover.


And finally added beautification.
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Axel
RV-4 fastback thread and Pics
VAF 2019 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weight out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk.
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  #448  
Old 11-30-2018, 11:00 AM
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ppilotmike ppilotmike is offline
 
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Default Looks great!

I really like the new throttle quadrant set up.
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  #449  
Old 11-30-2018, 07:18 PM
RhinoDrvr RhinoDrvr is offline
 
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Lookin’ good Axel!! When you’re done practicing, there’s a Red and Grey RV that could use that throttle as well as an ADS-B solution 😂
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  #450  
Old 12-21-2018, 06:10 PM
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AX-O AX-O is offline
 
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Catching up on posts. I have been sick so have not been able to fly yet. The plane is ready. Paper work and pilot to follow.

I called Kathy at EarthX and ordered a 48 inch Quick Connect and Charging cable like this one Click

I also got a Jump Pack like this one Click since we used one at OSH this year to start a plane during the airshow.

The plan was to run the cable from the battery to a place in the cockpit that I could easily plug into if I need to. fairly easy process. Used the avionics knot to clean everything up and velcro at the end of the cable for securing/quick release.

The battery pack is very light, has an LED, USB charging plug and electronic built in protection for reverse polarity, etc. Surprisingly the 48 inch cable weighted about the same as the battery pack. It is a bigger gauge cable than what I had before since you can plug into this one for starting. Hope I never have to use it but is there if I need it.


I also set the timing of the PMAGS and configured the "B curve" as shown below. Set the Max engine RPM to 2816, dropped the Max Advance to 33.6 deg and subtracted 1.4 deg on the curve shift. Will play around with this once I get more familiar with it. For now the instrument will remain off along with ADSB since I have to get back in the cockpit. Trying to minimize the info coming in that is not required.


Finally figure out the prop extension required. It ended up being 1 3/4 inches. The prop extension was installed with new bolts per Saber's installation instructions. The Whirl Wind 200RV prop was also installed. Prop cycle video here https://youtu.be/EmahtL-JdG0




Dont mind the F1 racer on the wall. Nothing to see there.


Dont mind the leg lamp either.









Last edited by AX-O : 12-21-2018 at 06:32 PM. Reason: Added pics
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