Thursday, January 19, 2023

Cowl modifications, fuel site tube, brakes

Michael continued with the cowl modifications to improve the transition to the propeller spinner and also improve the area where screws will be added near the cowl air openings.  Lots of sanding, filing, and epoxy work was involved, but it's looking good.

Michael doing some filing work on the top cowl

The brakes continue to give us some problems.  Thought we had them all bled, but realized the left rudder pedals seemed a bit mushier than the right, and a few days later saw some large bubbles migrate from the pilot's right rudder pedal into the clear tubing.  Air seems to be staying trapped inside the right brake cylinder on the pilot's side.  So we will attack this again later, but will be using a new technique suggested online which involves removing that cylinder and changing its orientation during the bleed process to help the trapped air escape. 

We also installed a NACA duct on the right side of the lower cowl.  This allows us to have a good dedicated air path to the Rotax regulators, as the B-side regulator is known to have issues if not cooled properly.  This regulator is attached to one side of the Rotax fusebox, which is located in the middle of our firewall where airflow may not be the greatest.  We are also planning on adding a larger heatsink to this regulator which will help with the cooling.   If later testing (during the summer) shows that this extra air is not needed, then we can use the duct to provide cool air directly to the engine, so it won't be wasted. 

NACA duct on lower cowl

A shroud for the header tank site tube was fabricated from aluminum, then primed and painted.  I'll be adding a diagonal hash pattern to the tube which will sit directly behind the fuel site tube.  Due to the refraction of light going through fuel, this makes it much easier to see the actual level of fuel.  
Hours: 12
Aluminum site tube shroud after a coat of paint

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