Baffles, continued

January 24, 2019 – I continued with the baffles.

I riveted the small doublers on the baffle for #4 cylinder, then went to fit the baffle. It fits tightly around the rocker box cover and it needed trimming so attach holes would line up.

 

I then located where I thought the oil cooler would mount. One detail on the plans sheet shows a reference 3/8″ margin from the edge of the oil cooler doubler to the edge of the baffle. So I located it there and back-drilled the holes from the doubler to the baffle. Then I removed the material in the baffle where the oil cooler would go.

All well and good…

Then there’s an oil cooler brace that has prepunched holes. Two issues…the holes are prepunched to #40; that’s fine, but the holes in the doubler that this brace matches up to are #30. Worse still, as I had everything located, these holes don’t line up.

Put the question out to the experts on vansairforce.net and learned two things. One was that I should wait to locate the oil cooler until the baffles are situated, the other was that maybe the doubler needed to be just 1/4″ from the edge of the baffle. That would make these holes line up. I’m less worried about the disparity between #40 and #30 holes; I’ll probably go ahead and make the rivets larger at that location.

I ordered a new CB-705A, which is the baffle with the oil cooler hole in it. I didn’t drill any other part yet…

There have also been huge issues with cracking at this location due to the weight of the oil cooler and vibration. I’ll be modding this area as almost everybody does. More on that later…

Time: 2:35

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Made engine control brackets

January 24, 2019 – I made the brackets that I needed to install the engine cables.

I ordered a 12″ x 12″ sheet of .063″ 4130 steel from Spruce. I made the new extended throttle cable bracket and the angle that mounts forward of the throttle quadrant to secure the cables there.

Here’s the old and new throttle cable bracket for comparison:

I’m waiting to get my modified mixture bracket back, then I’ll have all three pieces powder-coated.

Time: 1:20

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Working on control cables

November 15, 2018 – Well, I complicated my own life by going with a throttle quadrant for engine control. I’ll be so glad when this part gets wrapped up.

I drilled holes in the firewall at the suggested locations for the throttle, prop and mixture cables using my punch set. The holes are 1″ right now, just large enough to pass the cable nuts through. I believe the final hole sizes will be 1 1/8″ for the cable pass-throughs I’ll get from Spruce.

I bought a 48″ and two 52.5″ cables. When I got them I routed them through the firewall to test fit. I used closed-cell foam to protect the cable jackets from the stainless edges.

I already know the 48″ cable is too short for the throttle. As near as I can tell, I need 51″. I’m waiting to order until I’m sure about the rest of them.

I had to slightly re-clock the prop governor because the cable went over-center at full travel. I also bent the bracket for the governor for a straighter cable approach.

Along with figuring out what cable lengths I need, I also need to make sure those cables are secure so I can get an accurate idea for routing and their lengths. The cables will be secured behind (forward of) the quadrant, so I started prototyping a bracket for that. Here’s my first one:

…and my third:

I think this one may be in the ballpark. I also ordered Aircraft Spruce part #05-01437 which is an AN486 with a 10-32 thread. These should have a deeper throat for attachment at the quadrant. I wasn’t getting full travel at the quadrant because the shorter clevises were hitting the arms. They are on the way.

Time: 6:30

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Miscellaneous Firewall Forward stuff

October 17, 2018 – I realized it’s been a while since I posted an update, so here goes…

Engine control cables

I started assembling the parts for engine controls: throttle, mixture and prop. I started with the mixture, since it’s a fairly complicated bellcrank system that reverses motion. The first problem that I ran into was that the mount bracket for the bellcrank does not fit as advertised on my engine. Right where this bracket is supposed to go, there is a drain plug in a boss on my Superior cold-air sump.

I found online where someone else had this same problem. They started by grinding down the height of the plug. So I did that, but the boss that the plug is in will not allow the bracket to sit in place.

I decided to trim the bracket until it does fit. After everything is installed and works, I’ll take the bracket off and make a new one. You can see that I removed a lot of material. That’s fine.

So I assembled the bellcrank and moved on.

I measured for the three cables, since I am using a throttle quadrant instead of the traditional push-pull controls supplied by Van’s. I ordered some from Van’s and just got them today. I also drilled the holes in the firewall at the three recommended locations. They’re just 1/2″ right now. I’ll take them to final size when I start test-fitting the cables.

 

Fuel Flow Transducer

I figured out where I’d like to mount the Red Cube. It will be inline between the servo and the flow divider, and I’ll mount it on the engine mount behind #3 cylinder. I had the long fuel hose that goes there…I sent it to Tom Swearengen at TS Flightlines. He took care of me. I’m a big fan…

Oil Temp Sensor

I installed the oil temp sensor as required…

Engine Electrical

I’ve been slowly working on cables for the battery, starter, etc. The only picture I have right now is the copper bar between the contactor and the relay. I replaced the one bar I had with two that total .125″, which is closer to the plans.

I got in touch with a guy who was in town and bored (he posted on Van’s Air Force). He was looking to see if anybody needed a hand with anything. So he came over today to visit, and we took care of a short list of items I needed an extra pair of hands to get done.

We installed the firewall pass-thrus, and I needed to remove the manifold on the firewall so I could get fittings in it. We removed it, installed the required fittings, and reinstalled it. If I ever have to take that manifold off again, I’ll install nutplates.

Time: 13:10

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Installed CHT and EGT probes

September 7, 2018 – Today I installed the CHT and EGT probes. I’ve ordered a lot of small items from Spruce, and I’m kind of on hold with a lot of things. This I could do today.

Pretty straight-forward; I used some anti-seize to install the CHT probes. These probes from Dynon have a quick-disconnect feature.

The EGT probes use a hose clamp setup to hold the probes. I drilled  1/8″ holes in each exhaust pipe 3″ down from the flange on the cylinders. Insert the probe, tighten the clamp, that’s it.

Time: :50

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Worked on firewall pass-throughs

September 6, 2018 – I installed a couple of items on the firewall; the wiring pass-throughs and the fuel line connection.

I found the Avery pass-throughs at Aircraft Spruce, so I bought two of them. These will be for the wiring. As is usually the case, I’ll be running engine monitoring and sensing wiring through one, and heavy electrical through the other.

I put one pass-through in each upper corner of the firewall. I bought a set of punches at Harbor Freight. I drilled a 3/4″ hole using a Unibit to accommodate the punch.

Put the bolt part of the punch through, then crawled inside and put the die in place and tightened it down by hand. Went back outside and tightened the bolt until the hole was cut.

I used the flange to drill the screw holes, and deburred everything. Used firewall sealant on both sides, and clecoed the flanges into place. I’ll need help to install the screws, but that part is done.

I also installed the fuel fitting that goes through the firewall. I opted to use the doubler that they have you install on the firewall at the very beginning of firewall construction.  This doubler is for the optional Facet fuel pump, which I’m not using. This made more sense than installing another doubler just a few inches away when this one is not being used.

Time: 2:00

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Installed Prop governor

September 6, 2018 – I installed the prop governor.

I wasn’t sure about the orientation of the governor on the engine. So I did some online research, and found the orientation that seems to be correct. I definitely had to reclock the control head. With the governor in the correct position on the engine, the control arm faced down, when it’s supposed to be up. The instructions tell you how to reclock it.

You just break the safety wire on the top screws, loosen them, and rotate the head to the desired position. I went 180 degrees out from the original position. I also had to install the bracket for the cable, so I had to loosen those screws anyway.

I installed the governor on the engine. The nuts are pretty hard to get on to torque. I’m pretty sure this whole project is going to be that way, and get worse all the time.

Time: 2:15

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Installed heat muff

September 6, 2018 – I assembled and installed the heat muff.

The heat muff takes air heated by the exhaust and routes it to the cabin for some semblance of heat. I installed it on the only stretch of pipe that was long and straight enough to accept it: on the pipe from #1 cylinder. Wasn’t sure about this spot, but I’ve seen it on other airplanes, so…

I needed 5 1/2 hands to put this together, but I figured it out.

Time: 1:10

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Installed exhaust

August 29, 2018 – Well, that was pretty easy. I got the exhaust installed today.

I got the crossover tubes installed and torqued the pipes to 180 in/lb.

The hangers were pretty simple as well. Vetterman gives you clamps and everything you need to support the pipes at the exit.

I installed the lower cowl to check the space at the exit. Have lots of room there.

The pictures look like the pipes turn outwards, but that’s just the camera angle. They both point straight back.

I attached two angles at the aft corner bolts on the sump, then used the supplied hardware and rubber tube to connect to the clamps on the pipes. The clamps are supposed to be as far aft as possible to provide good support.

Once I got the vertical hangers in, I supported the pipes horizontally to each other. I had to cut the provided tubes because of the short distance between the pipes.

Time: 2:20

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Started exhaust

August 29, 2018 – It was time to start with all of the engine hookups.

I took the box from Vetterman out of my bedroom into the garage, and did a quick inventory. I had to run out and get some high-temp anti-seize, then I attached the pipes to the cylinders. Their instructions say to start with 3 and 4, then install 1 and 2.

The pipes are in place, but not yet torqued. I still have to install the crossover tailpipes.

Time: 1:00

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Engine is hung!

April 5, 2018 – A very nice day to hang the engine!

I got a good crew together today and we got the engine hung in no time.

Not much to say about it…started with the top bolts and then did the bottom. Had a lot of hands in there and a pro manned the hoist.

Thanks to Mel and Ann Asberry, Norm Biron, Carlos Ramos and Floyd Knudsen. After we got it installed there was lots of hangar flying and adult beverages.

Time: 10:00

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Engine delivered

April 3, 2018 – After its own well-deserved vacation, the engine finally arrived safely.

I’d been watching the tracking for the engine, and all of a sudden, it veered east. Then it showed Out for Delivery…in Virginia! After a couple of phone calls, it was redirected, and was delivered on April 3.

Opened it up and checked to make sure all was well, and that the serial number matched. Yep, it’s mine!

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