Wiring up the wings

With the wings finally on, we can now finish up all the wiring: the nav/strobe lights, pitot heat, autopilot on the wing, fuel senders, pitot and AOA plumbing. Took almost a day to wrap this up (8hrs).

Also had to finish the wingtips, wire them and test everything for operation:

 

The images below show how the wiring to the tax/landing lights were secured. Here is a place where experience really counts. For example, you don't want the power connection going to the lights ever touching the airframe. Consequently its imperative that you insulate it well. Harley (Glenn's brother) advised on how to insulate using wrap around the connection. Lots of small details took quite a bit of time (6 hrs).  

 



 

Here is the final product!

 

We test fired the strobes and landing/taxi lights. Everything works except for the wig-wag functionality. Realized that we need to get a new flasher module. Its on its way from B&C and once that's in, we got everything wired up in the panel!

Running Wires

Just wrapping up the final wiring that we can do at the moment. Lots of small details, including planning wire channels for future runs when we bolt on the wings. Finishing up connecting the panel switches (5 hrs):

Now since, the antennas are mounted and the GPS/VOR is in, we finally routed and connected the RG-400 cable (2 hrs). We went back and forth between using the 90 degree and straight connectors. Ended up using the 90 as was worried about interference with the aileron pushrod.

Also ended up finalizing how the pitot and AOA tubes would come to the fuselage and how would they be routed (4 hrs).

Wiring up the panel

The avionics shipping issue has been a nightmare, with the dealer plainly refusing to honor the deal. A big setback. I finally bought a bunch of lost avionics again :(.

 

 

Anyway, we have made some progress with doing the final wiring for the panel. Installed forest of tabs just behind the actual panel. Never realized I'd require so many grounding points. Also installed a connection strip for various connections to switches etc.

 

 

 

There are a bunch of Dynon boxes that need to be mounted. The ADS-B box goes on the wall behind the panel. The ARINC module as well as EMS box is on a horizontal mount I made between the panel the rear-panel wall. Finally, the transponder and the backup battery are accessible and mounted near the gear towers. 

 

Here is the panel that was finally bolted:

 



There are many things to be done before the panel is finished. For example, still need to pull the wires from the wing and attach taxi / landing lights, pitot heat, strobe etc. This will have to wait till wings are mounted. Similarly a bunch of wiring is left for the firewall forward portion (senders, CHT and EGT etc.). All in all at least 50 hours for all this work (probably more).

Progress towards the panel

This was supposed to be a pretty big week, as the panel and the components were supposed to arrive from the avionics. However, it appears that some of the panel components were lost en-route and now I am trying desperately to see what can be done about it.

Anyway, here is the progress for the last few days. Have been busy pulling wires across the fuselage as well routing the pitot/AOA/static tubing (5 hrs).

 

 

Also, threw the forward top skin on the fuselage to check the fit and get an idea of how things will be.  I ended up drilling the holes and deburring them as well (5 hrs).

 

Finally, also started to fabricate the double plate that would go with the comm antennas. Lots of small details that took fairly long to get right (5 hrs). The plates are now ready to be riveted to the bottom of fuselage. The riveting will happen once the airplane is on the gear.

 

Here is a snapshot of the panel that we received. Its missing switches and what not. I am not too happy with how this turned out. If there is a next time I would definitely choose a different vendor.





Panel

I have been researching and designing the panel over last few weeks. I like flying in IMC (that is besides Aerobatics) and did want to have IFR capable machine. This is quite a challenge if you are on a budget and want to keep things simple. After going back and forthe several times in past few months, here is what I decided on:

- Garmin 650 (GPS WAAS and VOR). This will be primary NAV source (VOR as a backup) as well as primary COMM
- Dynon skyview system with EMS, Autopilots, Transponder and GPS (GPS will be a back up)
- Trutrak Gemini as secondary EFIS
- SL40 as a secondary COMM
- GMA 240 as Audio Panel
- Dynon will also have backup battery (in case of an electrical failure)

Here is the panel layout that is currently being cut: