13.9.2 Autopilot Roll Servo Mounting

Posted on 11/27/2013 by admin

This entry is part 16 of 67 in the series 13 - Electrical / Instruments

I have decided to mount the autopilot roll servo between the whale tail and the landing gear bulkhead on the pilot side.

I could have made some hardpoints out of 1/4″ aluminum but then the plane of rotation for the servo would not have been the same as the aileron bellcrank. So I used some 1/2″ aluminum for the forward hardpoints.

Once I had tweaked the alignment, I mixed up some structural adhesive with some flox & cabo then bedded the hardpoints.

Once it cures, I’ll cover it with 2x BID and that will be one more thing done.

13.7.1 Avionics Shelf

Posted on 12/06/2013 by admin

This entry is part 10 of 67 in the series 13 - Electrical / Instruments

One of the traps that you can fall into when building an airplane is to purchase things way before you need it. With electronics, this can be especially troublesome since the radio that you buy today can be antiquated (or obsolete) by the model that comes out 6 months later.

Lately, I’ve been trying to figure out how all the different boxes which make up the avionics suite are going to fit on the avionics shelf. I don’t have most of the equipment yet since I don’t want to buy anything until I absolutely have to have to.

The dimensions are readily available but after spending a few hours drawing and playing with 3D CAD software, I decided to go old-school. I got some leftover blue foam and made mockups of the various boxes.

Here are the two communications radio & single navigation radio (on left), transponder, audio panel, dual AHRS (under audio panel), GPS, two trim controllers and Vertical Power VP-X Pro (under the GPS and trim controllers).

After moving things around and not being able to make everything fit, I decided that I needed more shelf space. So I made a sub shelf that will go above the VP-X.

This is the VPX sub-shelf (from the front).

Because the trim controllers have adjustments for the trim motor speed, they need to be accessible. So I made a stacked mount for them. Here is the view of the avionics sub-shelf from the rear.

And here is how the avionics boxes will be laid out (for now).

13.9.2 Autopilot Roll Servo Wire Routing Modification

Posted on 12/07/2013 by admin

This entry is part 9 of 67 in the series 13 - Electrical / Instruments

I couldn’t figure out the best way to route the wires to the autopilot roll servo from the right wiring duct to the servo. I asked Malcolm and he said to bring it forward to the whale tail and then back to the servo. But I wasn’t planning on that long of a run and the wires weren’t long enough. It’s not a huge deal to run new wires but that was a rather circuitous route. I asked about running them directly across but Malcolm wasn’t keen on wires that close to the gear retract cables. So I cut a length of .25″ aluminum tubing and glassed it in position.

Nice, short cable run, protected from any moving parts. Win/win.

13.8.1 Magnetometer connections

Posted on 12/11/2013 by admin

This entry is part 8 of 67 in the series 13 - Electrical / Instruments

Now that the magnetometers are mounted, it’s time to run the cables to them. The supplied wiring harness from Grand Rapids is 20 feet long. The magnetometers are in the left strake. The wires aren’t long enough to run down the right wiring duct so they’ll have to go down the left side duct. I checked with Ben at Grand Rapids and he confirmed that running the wires in the same duct as the communications antennas will not cause any interference with the magnetometers or radios.

Once I got the two harnesses organized, I ran them through the mesh sleeves. Then, because I didn’t want to find out that the antennas wouldn’t fit, I pulled the magnetometer wiring, both com antenna wires and both nav radio antennas at the same time.

Then it was just a matter of terminating the magnetometer end of the wires and connecting them.

13.2.2 / 13.6.2 Aft wiring complete

Posted on 12/13/2013 by admin

This entry is part 7 of 67 in the series 13 - Electrical / Instruments

Mostly. 🙂

Just about all the wiring in the aft portion is complete. That is, everything aft of the seats. The engine compartment was completed earlier. It the inside part that had me scratching my head. Lots of wires and trying to decide of the best routing for them.

Here’s the back of the inside:

On the very bottom/center of the picture is the roll trim motor. That’s not wired yet (I said “mostly”).

Above that are the two voltage regulators. One on the left is for the primary alternator and the one of the right is for the backup alternator.

Up the left side are the wiring bundles (blue) for the Engine Information System (EIS), navigation lights and power for the fuel level sending units.

Halfway up on either side are two small black boxes (with two white labels). Those are the fuel level sending units (one for each tank).

On the left side, to the left and slightly above the fuel sending unit is a terminal block for connecting various devices.

Above that (top/left) is the ground block for anything inside the aft cabin.

Here are the two voltage regulators.

This the right fuel sending unit and terminal block.

Closeup of the terminal block.

From the top:

Manifold Air Pressure Sensor Power Supply
Manifold Air Pressure Sensor Signal
Right Fuel Sender Unit Signal
Left Fuel Sender Unit Signal
Fuel Sender Unit Power Supply
Navigation Lights
Strobe Lights

All the way in the top/left is the ground block. This is connected to the ground block on the engine side of the firewall.

00 Flow chart – Year end

Posted on 12/22/2013 by admin

This entry is part 17 of 28 in the series 00 - Prep/Logistics

   1.    ✔︎ Read chapter one of your manual and review the construction DVD’s
   2.    ✔︎ Cut out Doghouse
   3.    ✔︎ Cut out and install premolded NACA scoops
   4.    ✔︎ Install Overhead plenum NACA (do not install plenum until flipping airplane)
   5.    ✔︎ Fit keel in airplane and then remove to install control system
   6.    ✔︎ Install wood hardpoints for control system in keel
   7.    ✔︎ Cut out and layup inspection covers in keel
   8.    ✔︎ Install nut plates to hold inspection covers
12.   ✔︎   Cut out nose gear door hinges
13.   ✔︎   Install top Triax pads on firewall for Continental engine
14.   ✔︎   Complete fiberglass portion of nose gear door installation
15.   ✔︎   Install Heater flapper valve and aluminum outlet tubes in oil cooler exit
16.   ✔︎   Cut out oil cooer inlet and outlet ducts
17.   ✔︎   Install front oil cooler ducts
18.   ✔︎   Install rear aileron control bracket to keel rear section
19.   ✔︎   Install aileron torque tube and control stick in keel
20.   ✔︎ Mid bearing support installed in keel
21.   ✔︎   Install main gear and nose gear cylinder
22.   ✔︎   Install AN fittings into main and nose gear cylinders (tape over the ends)
23.   ✔︎   Install flexible hydraulic lines between nose and main gear cylinders
24.   ✔︎   Fit and install battery tray
~~25.         Fit and install Landing Light Assembly (no landing light in the nose)~~
26.   ✔︎   Structural Adhesive front of keel in place
27.   ✔︎ Install front keel stiffening layups
29.   ✔︎   Install nose gear bushing plates
30.   ✔︎   Glass edges of canard cutout to seal it
31.   ✔︎   Fit and fair in nose access cover
32.   ✔︎   Install nose gear gas spring and shock assembly
~~33.   Install nose gear door cylinder and assembly~~
34.   ✔︎   Install RG hydraulic power pack
35.   ✔︎   Install MG pulley and cable assembly
36.   ✔︎   Install rudder pedals
37.   ✔︎   Fit instrument panel into airplane
38.   ✔︎   Install seat hardpoints
39.   ✔︎   Use Velocipoxy and micro to fair in back of windows
40.   ✔︎   Construct sump tank
41.   ✔︎   Glass side of canard bulkhead opposite the flange
~~42.   Install sequence valve assembly~~
43.   ✔︎   Install Dump Valve
44.   ✔︎   Install nose gear guides
45.   ✔︎   Install hydraulic power pack
46.   ✔︎   Install hard lines for RG system
47.   ✔︎   Install Center Spar
48.   ✔︎   Triax reinforcements between the center spar and the gear bulkhead.
51.   ✔︎   Place airplane on jacks and remove main gear
52.   ✔︎   Cut out fuselage to allow main gear retract, complete transverse bulkhead
53.   ✔︎   Install main gear bushings
54.   ✔︎   Triax over main gear bushings
55.   ✔︎   Permanently install steel bushings in gear legs and make aluminum spacers
56.   ✔︎   Install straws on MG for brake lines
57.   ✔︎   Install canard attachment reinforcements (triax)
58.   ✔︎   Install Canard bushings
59.   ✔︎   Complete all canard Triax reinforcements
60.   ✔︎   Install hinges on elevators
61.   ✔︎   Install hinge arms in canard
62.   ✔︎   Attach canard tips
63.   ✔︎   Install concentric torque tube
64.   ✔︎   Install counterweights
65.   ✔︎   Check balance of elevators
66.   ✔︎   Install elevator pitch trim actuator
67.   ✔︎   Install main gear
68.   ✔︎   Install main wings prep for strake install
69.   ✔︎   Temporarily install doors (hinges do not have to be completed yet)
70.   ✔︎   Fit lower strake
71.   ✔︎   Cut out baggage access opening
72.   ✔︎   Install lower strake bottom
73.   ✔︎   Fit top strake
74.   ✔︎   Remove wings to provide more space
75.   ✔︎   Glass dyvinicel sheet to make fuel tank baffles
76.   ✔︎   Cut out opening for gear and wheel well
77.   ✔︎   Fit gear and wheel well
78.   ✔︎   Cut out baffles a little larger than templates
79.   ✔︎   Glass top flange on wheel well
80.   ✔︎   Fit baffle bottoms to bottom strake
81.   ✔︎   Fit baffle tops to top strake
82.   ✔︎   Reposition all baffles in bottom strake and tack in place
83.   ✔︎   Glass bulkheads and baffles to lower strake
84.   ✔︎   Install hardpoint for fuel vent and main fuel line
~~85.   install sight tubes~~
86.   ✔︎   Install fuel caps in strake top
87.   ✔︎   Seal fuel tank with 2 coats of Jeffco or EZ-poxy
88.   ✔︎   Coat strake top with Jeffco or EZ-poxy in fuel tank area
89.   ✔︎   Cut wing access bolt hole
90.   ✔︎   Practice fuel strake top installation with partner
91.   ✔︎   Install strake top
92.   ✔︎   Cut wing from strake
93.   ✔︎   Remove wings
94.   ✔︎   Cut leading edge from strake that will go on the door
95.   ✔︎   Install door and glass leading edge of strake to it
96.   ✔︎   Install outboard end stake reinforcement
97.   ✔︎   Finish glassing fuel tank bottom seams-back of spar-strake top and bottom
98.   ✔︎   Pressure check each main fuel tank
99.   ✔︎   Complete finish work between strake top and fuselage
100.   ✔︎   Reinstall wings
101.   ✔︎   Complete finish work between strake top and wing
102.   ✔︎   Remove wings
103.   ✔︎   Flip airplane
104.   ✔︎   Finish glassing on exterior of fuel tank top seams
105.   ✔︎   Complete finish work between strake bottom and wing
106.   ✔︎   Complete glass work between strake top and inside of baggage well
107.   ✔︎   Install overhead fresh air plenum
108.   ✔︎   Fit main gear doors and install attach brackets onto gear legs
109.   ✔︎   Fill sand and prep gear legs for primer
110.   ✔︎   Complete all finish work on bottom of airplane.
111.   ✔︎   Prime and prep for paint
112.   ✔︎   Remove wings
113.   ✔︎   Flip airplane back onto it’s gear
114.   ✔︎   Install sump tank
115.   ✔︎   Install fuel plumbing between main tanks-sump tank-firewall fitting
116.   ✔︎   Install Fiberfrax and stainless steel on firewall
117.   ✔︎   Install oil lines to forward oil cooler
118.   ✔︎   Install rudder cable nylaflow in airplane from pedals to the firewall
119.   ✔︎   Bond in rear keel (whale tail) section and install rear aileron bellcrank in keel
120.   ✔︎   Install Aileron push/pull cables through firewall
121.   ✔︎   Install Aileron torque tube
122.   ✔︎   Install Aileron bellcrank and bearing brackets in wing root
123.   ✔︎   Install Rudder hinges
124.   ✔︎   Install rudder horn
125.   ✔︎   Install rudder return spring
126.   ✔︎   Install Aileron hinges
127.   ✔︎   Install rudder cable in airplane and wing nylaflow
128.   ✔︎   Install rudder pulley and cable adjuster between firewall and wing root
129.   ✔︎   Install winglet bottom
130.   ✔︎   Fit top and bottom cowling and flange
131.   ✔︎   Install Door hinges
132.   ✔︎   Install secondary lock in door
133.   ✔︎   Install key lock
134.   ✔︎   Fit door trim panels
135.   ✔︎   Install door gas springs
136.   ✔︎   Assemble seat backs to bases with seat hinges
137.    Install seat belt hardpoints
138.   ✔︎   Remove wings
139.   ✔︎   Engine installation.
140.   ✔︎   Fit fiberfrax and stainless to firewall and install
141.   ✔︎   Install front oil cooler lines and bracket on firewall
142.   ✔︎   Install secondary oil cooler
143.   ✔︎   Install electric fuel pump
144.   ✔︎   Plumb aluminum lines between firewall bulkhead fitting and fuel pump
145.   Install wiring
146.   ✔︎   Mount the engine mount on the engine
147.   ✔︎   Mount the engine on the firewall
148.   ✔︎   Fabricate oil access door
149.   ✔︎   install oil and fuel line plumbing from the airframe to the engine
150.   ✔︎   Install engine senders on firewall and wire
151.   ✔︎   Plumb flexible lines between engine and senders
152.   ✔︎   Jack airplane up and fit brakes to gear legs
154.   Check for toe in and camber. Shim axle to correct
158.   Installed prewired panel
159.   Connect panel wiring to premade harness Harness instruction
160.   ✔︎   Install Throttle , Mixture and Prop control cables
161.   ✔︎   Install pitot tube
162.   ✔︎   Install Static port
163.   Install Pitot/Static system tubing
164.   ✔︎   Install engine cooling plenum and runners to NACA scoops
165.   ✔︎   Cut exhaust exit in cowling
166.   ✔︎   Trim exhaust tubes and permanently install on engine
167.   ✔︎   Install prop and trim or modify rear cowling as necessary to fair in
168.   ✔︎   Install canard
169.   ✔︎   Complete control stick to concentric torque tube installation

13.0 Wire Labels

Posted on 12/22/2013 by admin

This entry is part 6 of 67 in the series 13 - Electrical / Instruments

Originally I was going to label my wiring using plan English labels. Oil Pressure Sensor, Fuel Pressure Sensor, etc. But the printable, heat shrink tubing is wicked expensive. And with the longer labels covering the wire, it made wires less flexible.

So I started searching for a different approach. I found a Navy document that had a section on wire labels. I made some minor changes since I don’t have to accommodate 38 miles of wiring, heat seeking missiles, etc.

This is what I ended up with:

In this case, the wire above would be for the Autopilot Pitch Servo. Specifically, the power to the Pitch Servo. If the wire were to connect through a terminal, then on the other side of the terminal it would be C2-1B-18.

The only downside to this method is that there is now a document that lists out all of the categories, devices and wires. But now all the labels are a uniform length and relatively short.

13.0 Electrical System Documentation

Posted on 12/23/2013 by admin

This entry is part 5 of 67 in the series 13 - Electrical / Instruments

Normally when I create these posts, I use the section number from the manual at the beginning of the title, i.e. “7.8.4 Main Gear Microswitches”. But the electrical system is not really part of the build manual. Chapter 13 is basically “install the electrical system”. 🙂 So lately I’ve been taking the easy way out and using 13.99 for the section number. But I don’t like that since it makes it harder to find posts on a particular topic. And I think that’s very important. So I’ve expanded on the section numbers for Chapter 13. It’s a work in progress so it will probably grow as I continue working. But for now…

13.1   - Antennas
13.1.4 - Glideslope Antenna
13.1.5 - Marker Beacon
13.1.6 - Transponder
13.1.8 - GPS
13.1.9 - ELT

13.2   - Instrument Panel
13.2.1 - Instrument Panel

13.3   - Electrical System Completion
13.3.1 - Introduction
13.3.2 - Basic Electrical System
13.3.3 - Trim, Speed Brake, & Speed Brake Warning
13.3.4 - Switches and Circuit Protection
13.3.5 - Avionics
13.3.6 - P-Leads

13.4   - Pitot - Static and Vacuum Instruments
13.4.1 - Vacuum System
13.4.2 - Static Port
13.4.3 - Pitot Tube

13.5   - Lighting
13.5.1 - Nav/Strobe Lighting
13.5.2 - Cabin Lighting
13.5.3 - Landing Lights

13.6   - Power Distribution
13.6.1 - Battery 
13.6.2 - Alternator
13.6.3 - GPC
13.6.4 - Starter

13.7   - Avionics
13.7.1 - Avionics Shelf
13.7.2 - Radios (Navigation, Communications, Transponder)
13.7.3 - GPS
13.7.4 - Audio

13.8   - Instrumentation
13.8.1 - EFIS
13.8.2 - Master Warning Annunicator
13.8.3 - EIS

13.9   - Control
13.9.1 - Trim
13.9.2 - Autopilot

The Big Build.

Building the Velocity XL-RG

Category Archives: 2013