Nose Gear Console

Did some final fitting of the nose gear console cover, and fabricated a fiberglass flange to hold a boot for the emergency gear extension rod pass-through.

Indicator System

Fabricated a control box for the led indicators that would sense based on positive voltage or ground, and provide dimming and a push-to-test button to test all the led's.  Took a little longer than expected, and I'd do this with an Arduino in the future.

Cable Management

Fabricated a quick stand-off bracket to help route the throttle and mixture cables to keep them from chaffing on fuel lines.

Canopy Hardware Fabrication & Installation

Fabricated some brackets to attach gas struts to hold the canopy open along with some canopy safety catches and handles.  Used 40lb 9.65" extended, 3.54" stroke struts from McMaster-Carr.

Rough Idle Troubleshooting

Spent some considerable time troubleshooting a rough/loping low idle.  Ran fuel flow tests, cleaned all the fuel injector nozzles, checked for bubbles in the fuel line from the fuel pump to the flow divider, inspected all plugs, and replaced all ignition cables on electronic ignition side.  Traced it down to the vacuum advance on the electronic ignition.  At low idle, the high vacuum was sensitive to the pulses from the cylinder cycle since the vacuum port is so close to the intake valve on the cylinder.  Ordered a .004" Snubber from McMaster Carr and put that right on the vacuum sensor port, and the idle smoothed right out.

Spent some time making brackets and cleaning up the ignition wire routing while I was at it.

First Engine Run

First successful engine run today.  Had some issues on trying to run it on the weekend, and traced it down to a few loose fuel connections.  Still some tuning to be done, but it's getting there.

Heat Shield

Made a heat shield to protect the throttle and mixture cables from the exhaust, as well as keep the fuel servo and firewall cool. Made it out of .022 6061 and used the adhesive backed Zircoflex III over it.

Oil Cooler Hoses

Re-made the oil cooler hoses to accommodate the new oil cooler location and made a few brackets to secure them and the throttle cables.

Plenum Ducts

Finished molding and glassing the left duct, released the glass ducts from the molds and finished trimming them up. Had to dissolve away some of the foam using gasoline to get it out of the duct.

Plenum Duct

Started fabricating the right plenum duct to route air from the armpit scoop to the downdraft engine plenum. Duct will be attached to the armpit scoop with 4" scat. 

Oil Cooler Mount

Finished fabricating a mount for the oil cooler and attached it to the right rear baffling.

Engine Plenum

Been back at it, working on fabricating an engine plenum. Created cardboard templates, then cut and bent .025 6061 T6 aluminum to match. 

Drilled and attached nutplates for #8 screws. 

Wheel Maintenance

Disassembled and inspected left main wheel, replaced tube, re-packed bearings. Also replaced front canopy microswitch.

Throttle body & controls / Intake Filter

While the throttle body was off to install the stainless box for the firewall, I took the opportunity to modify the throttle cable bracket to reduce the amount of angle placed on the mixture control cable.  It previously had enough angle to cause some stiffness in the controls.  Hooked everything back up, tried it out, and it works perfectly now.









Also finished cleaning up the intake filter assembly, which is all ready minus a few bolts I need to order.

Firewall

Finished fabricating the stainless box for the firewall and mounted it up.  Had to take off the throttle body to get it in there, and it still wasn't easy at that. 

EIS Sensors

Finished installing MAP sensor for the engine monitor, and MAP advance sensor for the electronic ignition.

Wheel maintenance

Regreased right main wheel bearings, installed new tube, reinstalled tire, torqued everything to spec, and finished reinstalling on plane.

Wheel Maintenance

Took apart right main wheel to replace tube, and found corrosion.  Cleaned up the corrosion and repainted I/A/W Cleveland manual.

Misc

Installed oil dipstick tube, cut dipstick to fit and filed off old oil level lines. Fabricated, primed, and painted rear control stick.