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Fuel System Electronics Wiring
Installed molex connectors on fuel probe and fuel flow transducer and connected components to EMS harness and SkyView circuit breaker. Attached voltmeter input of EMS box to main bus bar. Ran firewall forward wires of EMS harness through gromet to…
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Throttle Bell Crank – Part 1
Because we are planning to use a traditional push-pull throttle (instead of a Sonex throttle quadrant) with the AeroInjector, we needed a way to reverse the throttle direction. Assembled throttle bell crank and created mounting bracket from scrap 2″ and…
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Engine Installation – Part 1
Continued working on Sonex FWF manual for the Jabiru by marking and trimming cooling fins on cylinder #1. In lieu of further trimming cylinder fins to fit spark plug CHT ring sensors, will opt to use #8 ring terminal sensors…
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Thrust Line Measurement
Verified engine alignment before moving forward by leveling fuselage with saw horse under tail and setting up laser level though center of crank. Measured bottom front corner of fuselage at 22.75″ from floor and center of crank as 40.25″ from…
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Firewall Forward Fuel System
Began working on firewall-forward fuel system by bending solid fuel line for drain branch. Ran -6 fuel line behind upper part of engine mount then bent line to come forward of bottom part. Created a drain cock mount out of…
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Wing Root Wiring
Attached wing tip lights to tip light fairings then installed DT connectors. Installed lights and fairings onto tips of wings. Terminated wing root wires at bulkhead connectors and tested functions. Reinstalled pneumatic bulkhead fittings for RH wing. Installed CHT/EGT harness…
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Avionics Sub-panel – Part 2
Created mount angle for EMS and ARINC module from scrap 0.032 sheet due to lack of clearance for modules with connectors on both ends. Riveted nut plates to vertical mount and then riveted mount to avionics shelf. Laid out backup…
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Avionics Sub-panel – Part 1
Created avionics sub-panel (shelf) from Z04-03 stock. Made mounting hinge pieces from -5 piano hinge to allow for more adjustability. Mocked up shelf locating behind panel and in front of fuel tank and pilot drilled hinges to upper longerons then…
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Circuit Breaker Wiring – Part 1
Began terminating panel wires to RH panel cover and circuit breakers. Connected master relay, master switch, and avionics switch wires to bus bars then connected available components to top of circuit breakers. Screwed RH panel cover into place onto panel…
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Circuit Breaker Mounting
Bolted Ram mount base to RH panel cover using AN3 hardware. Cut copper bus bars to size and drilled circuit breaker holes at 0.8 inch spacing. Installed circuit breakers into RH panel cover then secured bus bar onto bottom terminals…
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Main Switch Panel Wiring
Created harnesses for main panel switches leading to circuit breaker panel and wing root connectors. Laid out wiring path for each wing root connector and placed securement points. Installed main switch panel into LH side of panel and tested panel…
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Panel Lights Installation
Fabricated panel lights harness for panel light dimmer using Molex connectors to save space behind panel. Opted to branch out individual harnesses for each device needed the dimmer switch rather than bundling components together. Made one extra panel light circuit…