Engine Mount, Pitch Servo, Schematics

We temporarily installed our new nose-gear engine mount see how how it fits, and while it was tight, it did fit.  We had to add a few washers behind the lower mount point, but this was not unexpected.  We checked the nosegear and it fit nicely.  The firewall was removed for now as we are planning on making a template to help trim the top of the firewall once we can determine how it meets up with the cowling.  

Temporary fitting of engine mount & nosewheel

Since we had the engine mount attached, we decided to see how the Rotax ring mount mates to it.  Unfortunately, we ran into a problem.  The shock-mount isolators (Large rubber isolators) that we purchased from Rotax didn't fit.  We contacted the factory and found that these parts were unique and we neeeded to purchase them from the factory instead of Rotax.  So we returned the Rotax parts, and are now waiting for the new parts to arrive from Just Aircraft.  So we are in a bit of a holding pattern for now until the new parts arrive.

One other thing we did was remove the pitch servo and change out 4 bolts that attached it to a mounting bracket (these were a little too long).  The new bolts were torqued, and the assembly was remounted in the back of the plane.

Pitch servo with new bolts

In the meantime, Michael has been spending many hours (days) putting together the schematics for the wiring using KiCad.  A lot of time has been spent digging through all the manuals to make sure we get the wiring correct, and much time was spent sourcing parts like switches, circuit breakers, etc.  Hours: 20  

Fuel lines and hoses

 Several flexible fuel hoses were fabricated on the supply side, including all the hoses between the header tank and the fuel pumps.  We used Jegs Pro-Flo Extreme hose which is a step up from standard synthetic rubber.  The hoses have good compatibility with fuels that contain ethanol (even supporting E85 fuel).  Not quite as nice as PTFE fuel hoses, but not as expensive, either.   Each hose is unique as the length of hose and type of hose-ends were specifically chosen for each hose.

Attaching a hose end

Fuel hoses to the gascolator and  fuel pumps

Fuel hoses to cut-off switch

A 3/8 inch aluminum fuel line was installed along the left side, running from the header tank to a spot near the footwell.  6AN tube nuts were installed and the tube ends were flared, as they will connect to fuel hoses with 6AN connectors.  

Return fuel line

Return fuel line runs

Lastly, another flexible hose was made to go from the 3/8 inch return line to the header tank. 

Hours: 12

Hardline to fuel hose connection on return line

Brakes and Panel

Finally got the parts in to finish installing the brakes.  We needed a 90 degree fitting on the landing gear and a straight fitting on the brake caliper.  The 10" hose fit perfectly and made for a nice clean installation.

Brake Line Installed

A lot of time was spent laying out the instrument panel and we're closing in on our final design.  We've started doing our wiring diagram (in KiCAD) and this will help us determine how many circuit breakers and switches we need.

Most recent Panel layout

Hours: 8

Misc Work on Various Parts

 In order to set the brake/rudder pedal position, the rudder was re-installed on the vertical stabilizer.  3/16" holes were drilled in the horn to allow the rudder cables to be attached using shackles.  The Rudder hard stops were adjusted with a grinder to allow +\-30 degrees of motion.  Attention was then moved to the rudder pedals.  A turnbuckle was attached to the two outside rudder pedals.  With the rudder pedals 6" from the firewall the correct rudder cable length was determined and the cable was cut to the length and a thimble was swagged.  The plans didn't call for rudder return springs, but we added two springs to the rudder pedals that attaches near the firewall for this function.

Rudder Pedals with Turnbuckle and Return Springs

The elevator trim tab and trim servo were installed on the elevator.  The trim servo was connected to the imbedded wire we installed earlier in the elevator. 

Trim Tab and Servo installed

A cover for the trim servo was designed quite awhile ago.  The part was 3D printed but needed to be finished quite a bit.  The 3D part was sanded and then epoxy filler was added to the surface.  After a lot of sanding the part was primed.  After the primer dried, the part was painted to match the elevator with a coat of Vestal White paint.

(top) original 3D Printed, (bottom) Primed Part

Painted Trim Server Cover

We're still trying to find the perfect part for the brake lines that go from the Grove gear to the brake calipers.  We've settled on a 10" hose with 90 Degree fitting on one end and straight fitting on the other.  Parts have been ordered and we are waiting on delivery.

A lot of time has been spent on the FreeCAD designing the panel.  Still waffling on using either Klixon CB or Blade style fuses.  Each has its merits.  Currently leaning toward using the Klixon CBs.

Hours: 20

Header tank and fuel lines

A mounting bracket for the header tank was previously modified with a notch to allow it to be lowered.  This notch needed to widened to provide better clearance from the adjacent tubes, and this was done with a cutoff wheel and grinder.  

Notch widened on mounting bracket

Once complete, the notch was great, but the beautiful shiny black finish was messed up as expected.  So the part was sanded, then touched up with primer and some more shiny paint to bring it back to its former glory.  After painting and drying, the header tank was reinstalled with Adel clamps.

Repainted header tank reinstalled

Additional work was done on the fuel lines.  A 3/8 inch aluminum fuel line was carefully bent in a few spots using a pipe bender, and installed on the right side of the plane, running from the fuel cutoff switch to the header tank.  A 1/2" wide Adel clamp spacer was fabricated and installed in one tricky spot to ensure the fuel line was positioned correctly as it passed through an opening under the rudder cable.  We will be using flexible fuel hose for connections to the the rigid fuel line to account for vibrations. Hours: 15

3/8" fuel line installed

Fuel line installation