ADAHRS Mount and Pitot Line Bracket

The ADAHRS units need to be mounted in the same axis as the airplane and since the sub-panel sits at an angle I designed a mount for them.

The ADAHRS mount is simple, two extrusion pieces make up the legs and the rest I bent from sheet metal. The second ADAHRS will install above this one in the empty holes.

The side view shows the different lengths of the legs which makes an angle in the mount. This angle allows the ADAHRS to sit straight with the aircraft while mounted on the angled sub-panel.

I added a piece of j-channel to the back to prevent any vibration movement in the plate and thus the ADAHRS unit.

Once the ADAHRS was installed I could finish running the Pitot, Static, and Angle of Attack lines.

I made a small bracket to hold the pitot line Y-fittings. I didn't want to drill any holes in the small flange of the longeron so the bracket actually installs on the instrument sub-panel flange and then a leg bends aft to attach the fittings. Having the Y-fittings allowed me to install 90 degree connectors into the ADAHRS which provides more clearance for the big screen that is going to be installing in front of it. I just need to go back and add silicon tape to the tubes to prevent any abrasion against the outer skin.

Finished Flaps and Other Stuff

I finished up the flaps on Saturday. These were a really easy build and they look great. I riveted the trailing edges with proseal and with the rivets altering directions, facing up, facing down, facing up.... I did this to prevent any warping in the part during riveting. (I also did this on all the other trailing edges I have made, so nothing new). I laid some blankets down inside the fuselage and stored them in there for now.

Saturday June 15th - 4.25hrs - Finished Flaps, Riveted trailing edges.
Sunday June 16th - 5.25hrs - drilled skins, pitot tube mount, drilled holes for pitot lines, installed fuel tank

Finished Flaps Total Time = 26.25hrs

I installed the LH Fuel Tank yesterday, RH will come later. This was easier than what I thought it was going to be. I imagined lots of sweat and grunting to be required, but everything lined up really well. I first spaced them up using boards underneath the jigs they were sitting in and then after lining up the first hole I inserted a cleco into the nutplate to hold that end. I then raised the other end and did the same. I few more clecos and everything was lined up. Then I started installing the 56(?) screws...there were a lot.

I drilled out the LH skins and I got some help marking holes I drilled. Then we did the big cleco migration, where every cleco moves over one hole, to final drill the unmarked hole it was previously installed in.

 

 

 

The pitot/AoA lines are installed. I am using the Pitot/Static kit from SafeAir1. It provides tubing, connector, etc for cheaper than if you buy the stuff seperately (trust me I researched it). The tubing is nylon and can withstand -40F to 200+F, very durable. I had to drill new feed through holes for the green line, which will be my pitot line. The blue line will be my AoA line and I used the existing feed throughs made per the plans.

 

 

I worked on my pitot mast installation. I am using the Gretz pitot mast kit to install the Dynon pitot. The instructions for the install are decent, but it leaves a lot up to you, which was fun.

I used an old rib part I messed up on to scavenge an angle bracket.

Here are the 2 main parts. The angle bracket and the backing plate. (Note: This pic was post drilling, the parts don't come with holes)

 

I match drilled the backing plate to the spar first, removed it, then clecoed the skin in place. Reclecoed the plate to the spar on the outside of the skin and with the angle bracket clecoed to the spar I match drilled through the plate, skin, and bracket at the same time.

A picture with the parts clecoed in place. The skin will install over this.

I am installing in the third bay from the wing tip on the outboard rib.

Wings, Leading Edges

Time for an update. Working on the wings so far is pretty easy business. Although each task drags on longer than expected. Clecoing the leading edge assemblies and deburring holes, all takes longer than the estimates I imagine. After deburring the 1.3 million holes in the wing skins one day I found my fingers to be bruised the next morning from the repetitive twisting of the drill bit, a good opportunity to change the labor to dimpling. There really isn't anything frustrating or monumental so far with my progress on the wings. I have decided to wait on installing the leading edge lights. I am 99% certain I will be installing the Duckworks 70watt HID's on each wing, but honestly I just don't want to slow down, purchase, and install them right now. So I'm waiting. I also decided to not install the factory stall warning. I will be installing the Dynon system with angle of attack indicator and audible alerts, therefore I see no reason for the factory stall warning. The AoA gives a visual indication to the approaching stall and can be used to find best climb and final approach speeds. The audible alert is an absolute requirement for me and without it I would keep the factory stall warning for only that reason. Why not install both? Good question. I decided its just one more thing to break, I don't have to cut an opening in my leading edge (possible water access), I won't have a little tab sticking out to get hung up on and damaged, I won't have an access hole cut out in the lower skin (cause of other possible issues). On the Dynon system the AoA is measured from the pitot tube so this allows a single install and no new holes in the wing.

I learned a new way to remove the protective blue plastic from large flat pieces. Just roll it up. I took a PVC pipe peeled back a little of the plastic and started rolling...a lot easier.

Dimpling the ribs was easy with the pneumatic squeezer. Dimpling the leading edge skins was easy once I turned them over and switched the male and female dies from top to bottom. See pic.

So after weeks of drilling, deburring, dimpling, deburring, dimpling, clecoing, deburring....I had to start riveting something, so I started riveting the LH leading edge and so far it is turning out really nice. Also as a note. There are several nights I could only squeeze an hour in and it's amazing what you can get done in an hour when you know exactly what your going to do when you walk in the shop door.

Date Time
9 1.0 clecoed leading edge
10 1.0 clecoed other leading edge
12 3.75 deburr wing skins, drill leading edge assemblies
13 3.0 deburred RH wing ribs, dimpled RH wing ribs
17 3.25 deburred and dimpled LH wing ribs, install bolts in spars
21 4.5 deburr and dimple LH leading edge, reassemble and start riveting
22 1.0 rivet LH leading edge

Also, my daughter hung out in the shop with me on the warm days to help build the plane, but she just kept falling asleep on the job.