Archive for category Panel/Wiring
Still More Leading Edge and Wing Prep (12/11/10)
Posted by Ethan Jacoby in Construction, Leading Edges, Main Structure, Panel/Wiring, Spars, Wings on December 11, 2010
5.0 Hours -
Time really flew by while I was working on the plane today. I started doing some simple, repetitive things like deburring, dimpling and countersinking, and, the next thing I knew, I had been working for 5 hours!
I started off by finishing up my countersinking on the left main spar. Since the left leading edge was completely assembled except for the new inboard rib, I needed to get all of the leading edge attach holes countersunk before I could start working on drilling the new rib. Since the holes in the leading edge skin were already dimpled, I needed the corresponding countersinks in the spar completed to ensure that the leading edge would fit tightly on the wing.
Once the left spar was countersunk, I clecoed the leading edge on. Before inserting the new rib, I deburred and fluted it. Then, I marked a center line all the way around the rib on the flange. This line will be visible through the holes in the skin, ensuring that I have the rib appropriately located before drilling.
The left leading edge went back onto the wing, again, to drill the new inboard rib.
I drew a line down the middle of the flange on the new rib...I will be able to see this line through the skin and ensure that the rib is being drilled properly.
After the line was drawn, I inserted the rib into the leading edge/wing. Once I could see the line on the aft rib flange through the holes in the spar, I used a 12” #30 drill to drill the holes in the aft flange using the holes in the spar as a guide. Then, it was on to the #40 holes that attach the rib to the leading edge skin. Since I could see my line, it was easy to line-up and drill the flange.
The centerline on the rib was easily visible through the holes in the skin.
Once all of the holes were drilled, I removed the leading edge from the wing, and finished the new rib by deburring, dimpling, scuffing and priming it. While waiting for the primer to dry, I did some more deburring and dimpling on the main wing structures. After the primer dried I riveted the new rib and joint plate to the left leading edge.
The top rib is the old rib with holes too close to the bend. The bottom rib is the new one...notice the holes are located properly this time.
Ready to rivet the new inboard rib and joint strip to the left leading edge.
Next, I installed the stall warner and ground wire into the leading edge. Two bolts hold this in place, and the assembly can be adjusted up or down slightly to ensure that the switch can trigger. I also installed the wire that runs from the warner into the fuselage. However, for now, this wire will just be coiled inside the wing structure with no terminal installed on the fuselage end. Before leaving the stall warner, I used my multimeter to test the continuity on my ground connection.
Then, I continued my never-ending task of deburring, dimpling and countersinking the spars and wing structure.
Finally, I clecoed the leading edges to the wings for the final time. Next time those clecoes come out, they will be replaced by rivets (finally!).
My girlfriend was playing with my camera and taking bad pictures of me...
The wiring for the stall warner runs through a snap bushing in the spar.
The leading edges are clecoed onto the wings for the last time. Next time the clecoes come out, they'll be replaced by rivets!
More Countersinking and Wing Prep (12/10/10)
Posted by Ethan Jacoby in Construction, Leading Edges, Main Structure, Panel/Wiring, Spars, Tools, Wings on December 10, 2010
2.3 Hours -
Tonight, I resumed countersinking the left spar. I finished countersinking the bottom of left spar and the leading edge portion of the top of the spar. To do the top, I had to remove the outboard skin. Now, I just have the top/inboard of the left spar and the entire top of the right spar remaining to be countersunk.
Once I finished countersinking for the evening, I cleaned the spars with acetone and sprayed some self-etching primer to cover the exposed aluminum in the countersinks.
After countersinking the main spar, I cleaned it and sprayed some self-etching primer.
Ready for a break from countersinking, I decided to make the ground wire for the stall warner system. This was fairly quick to complete since all I had to do was to cut a 3.5 inch piece of 18 gauge wire, strip both ends, and crimp on terminals. To crimp the terminals, I ended up buying a ratcheting crimper from SteinAir. The dies on the crimper are interchangeable, and I purchased dies for both RBY and BNC terminals.
I bought this ratcheting crimper from SteinAir. It has dies for both RBY and BNC terminals.
Nothing complicated...the stall warner ground wire is a 3.5 inch piece of 18 gauge wire with terminals crimped on each end.
Finally, I started deburring and dimpling the left wing structure. Trying to break up the monotony, I would deburr a rib and a portion of the rear spar, then dimple those sections. Changing tasks like this seems to help me work longer. However, there is still a lot of countersinking, deburring and dimpling left to do in the wings.
Right Spar Platenuts Finished (6/25/10)
Posted by Ethan Jacoby in Construction, Panel/Wiring, Spars, Wings on June 26, 2010
1.3 Hours -
Although the garage was hot, I managed to spend just over an hour finishing the platenuts on the top of the right spar. As before, I had to countersink the holes for the rivets, attach the platenuts, and countersink the center hole for the #8 screw. Once this was done, I primed the countersunk holes.
For breaks in the “fun’ that is countersinking, I started finishing the edges of my tie down spacers. For now, I just used a vixen file to smooth the outside edges. I’ll still need to smooth the inner, lightening hole edges.
I also received my first panel instrument today, a Garmin Aera 510. My girlfriend works for a Garmin fitness dealer and, even though they only sell Garmins for running and cycling, she was able to get me a great deal on the 510. This GPS will serve as my backup GPS. It may even serve as several other backup instruments since I’m building a VFR only airplane. It has an incredible amount of functionality built into such a small box. In addition, the 510 has built in XM weather. While I don’t plan on subscribing to XM, I figured it may be a nice option to have available once I start doing longer cross-country flights. The only decision now is whether I mount it in an Airgizmo panel mount, or make my own mount somehow.
Garmin Aera 510
Although small, the screen is surprisingly easy to read.
Less than an inch thick, but a little heavier than I expected it to be.
Panel Planning/Dreaming
Posted by Ethan Jacoby in Panel/Wiring on April 16, 2010
I’m getting way ahead of myself, but recently I’ve starting thinking about panel design quite a bit. Granted, the electronics/avionics available now will probably be outdated by the time I actually get around to building my panel, but it might be good to start thinking about it so that I can start watching for good deals on EBay or used avionics dealers.
My goal is to have an all electric panel…no vacuum pumps in this airplane. Besides, modern EFIS are almost the same price as steam gauges. Plus many EFIS are all inclusive. One box contains all the flight and engine instruments, GPS, autopilot, and altitude encoder. Some can even connect to, control, and or display information from radios, traffic avoidance systems and external GPS. I also think that installation of a modern EFIS, along with a couple of backup instruments, will be less complicated than a traditional panel.
With this in mind, my current EFIS choice is the MGL Odyssey/Voyager. MGL’s innovation and low prices are impressive. They are constantly cranking out new products and upgrades to their current line. If you want to keep the panel simple, buy and Odyssey or Voyager, attach it to a radio and a transponder, and you are ready to go. Dynon also offers a great product that is competitively priced, but the ability to integrate a Vertical Power VP-X electrical system may have sealed the deal for MGL.
MGL also offers a comm radio and there are rumors of nav radios and transponders in their future. An all MGL panel may be in my future. However, for now, I’m looking at a mix of MGL and Garmin.
Below, is a rendering of the panel I’m currently thinking about. It was designed using the trial version of XPanel 5000 available from xpanelsoftware.com. While I’m currently using the trial version, I’ll probably purchase the full version soon. It seems like it will be worth the $60 price tag.
My first attempt at planning my panel. I'm sure I'm missing things, but the whole thing will probably change anyway.
The cornerstone of the panel is the MGL Odyssey. With a 10” display and keypad, it takes up a lot of space. Right now, I’m not sure how the understructure of the panel is laid out. If the Odyssey is too big to fit between ribs, etc., I’ll go with the Voyager instead. The voyager is identical to the Odyssey, except that the display is only 7.5”.
I’m planning on a single comm radio for now. The MGL V10 is impressive for the price. Others I may consider are the Garmin SL-40 and the ICOM-A210. I’ve also included a Flightcom 403 intercom (so I can have a stereo music input) and room to add another radio in the future.
The transponder is a Garmin GTX-327. I like that it is solid state and has a digital display. However, due to price, I may go with the cheaper, analog Garmin or even a used King or Collins.
Even though the MGL has a built in GPS, I’ve included a Garmin Aera as a backup. It seems that everyone has one or two backup GPS in their panel and I’m still not sure that this is needed for a VFR plane. I may end up just buying a cheaper handheld that stays in the flight bag and only comes out if the EFIS fails. However, the Aera is a nice unit that can be integrated into the MGL.
For backup gauges, I’m only going to have a altimeter and airspeed indicator. Again VFR only…I’m going to be looking outside, so I don’t see the need for dual, independent EFIS. Having said that, I did leave space on the panel for a separate EFIS like the MGL Xtreme or Dynon D-10. The MGL Odyssey/Voyager also have a VGA out, so I may use the empty space on the right to install a passenger display (such as found in car entertainment systems). This will allow the passenger to have their own view of the EFIS. However, they will have no control of its functions.
I’m planning on trim controls on the pilot’s stick. However, I’m going to mount rocker switches and indicators on the passenger side. Cabin air/heat, a power jack, and an audio input will also be on the passenger side.
I would love to use the Vertical Power VP-X as the backbone of my electrical system. It integrates with the MGL EFIS and also includes trim control, variable trim speed, flap controller, wig-wag, and a lot of other nifty features. System status, voltage/amps, trim/flap positions, etc are all displayed on the EFIS. The price is steep at $1800, but there is some savings in the installation versus using a traditional system of breakers/fuses, etc. With the VP-X, power for all components is routed from the battery/alternator to the VP-X then to the component. Switches are also routed to the VP-X. Using the EFIS, the VP-X is setup so that it knows what each switch controls and what value “breaker” to use.
Along the top of the panel, I’m planning switches for magneto/starter, master/alternator, avionics master, fuel pump, nav lights, strobes, landing lights, taxi lights, autopilot, and panel lights. At the bottom of the panel, I’ve got the all important throttle and mixture controls as well as a switch for the flaps (not sure where the best place for this is). I’ve also included an ELT remote panel, but I have no idea what the ELT requirements will be in a few years or what ELT I would want.
What am I missing? I’ll up date this periodically as I make changes in my plans or when new equipment hits the market.
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