Headliner, Vents, Soundproofing, Visor Fix

Around Easter my In-Laws visited and between the Easter activities my Father In-Law and I worked on the airplane. Since I had help I focused on the headliner. A much easier task to do with two. We used automotive headliner adhesive and just followed the directions on the cans (yep took more then one can). And it turned out great.

Applying the velcro strips to the headliner.

With the velcro strips attached to the back of the headliner and mated to its other half. We removed the adhesive backing and carefully placed the headliner into position. Then we had to remove the headliner and go back and push really hard on the strips that were now adhered to aircraft top. This really helped the strips get a strong hold to the cabin top.

After the headliner was in I had to place the seat and interior panels in the plane to see how it all looked. Looking awesome!

I wound up finding that just adhering the vent to the fuselage skin was going to wok better then how Aerosport planned on it being installed.

Soundproofing going in. Note to future builders: install the lower soundproofing, then the lower panel, then the upper soundproofing. The top of the pael screws into the longeron and the soundproofing can block access to the screw holes. Obvious, I know. But trust me, it's a pain if you don't do it in the right order.

Here's a picture of the little brackets I made to attach the ADEL clamps that support the wire bundels as they pass through the frame holes.

Once I sat in the front seat for the first time I immediately noticed that the visors were going to be a problem in their standard installation configuration. The seats sit much higher then I thought they would causing your head to be really close to the visor's post as it hung down right in front of you. So I came up with a solution. If you look closely I made a small 90 degree bracket that rotated the visor mount up and forward out of the way of the seat occupant. A simple and effective solution to the problem. Painted it black and screwed it in place. Works great.

Now the visor post is rotated up and out of the way.

Rudder Pedals and Sound Panels

Dates and Times
Sun 13 -4.0hrs- made template for close out panels, made attach tabs, worked on rudder pedal install

Mon 14 -7.25hrs- Day off work, thank you Columbus
Deburr, dimple, rivet tabs in place using blind rivets
Cut sound panels out
Match drilled panels
Pick up holes in firewall...drill using unibit backed with wood
Paint panels black
Mask and paint fitting in airplane
While drying. Run rudder cables.
Glue foam to back of panels using 3m Fire Sealant
Install close out panels
Tues 15 -1.5hrs- installed sound panels, insulation, rudder pedals
After a little hiccup in building the rudder pedals they are now complete and painted...yay! I just left the doubler plate a brushed aluminum and they turned out really nice.

Installed the rudder cables.

I am installing soundproofing throughout the airplane and one of the noisiest areas, of course, is the firewall. Although I did not want the soundproofing touching the firewall directly, due to heat issues (also if you can have a dead air space between the aircraft and soundproofing it works just that much better), so I created some mounting clips that sound deadening panels will attach to . If you look really close at the picture below there are four clips on each side, highlighted with torque stripe orange to assist in my match drilling, that are attached to the firewall stiffening angles. These clips hold the sound panels off the firewall about 1.0in. I should mention that I am also installing a fire barrier on the forward side of the firewall to reduce heat exposure during normal operation and engine fire. So the total stack up starting from the front will be: stainless steel foil, 0.25" fiberfrax batting, firewall, dead air space, soundproofing foam, 0.020" aluminum sheet.

Everything installed! Just imagine the instrument panel, center console, carpet, and side panels in place....

A close up of the panel shows the cut out for the brake lines and how the sound panel is made of the 0.020" aluminum and 0.5" thick soundproofing foam all held off the firewall by the attach clips. Note one of the screws located adjacent to the brake lines.

Now that the rudder cables are installed I was able to install a few floor close out panels.

Stuff I Use

I wanted to document some of the items I have purchased lately for the plane.

 

I bought a Ray Allen POS-12 Position Sensor for the flaps. This sends an electronic reading to the EFIS telling which position the flaps are in.

 

I bought a MATCO PVPV-D Parking Brake. With this purchase I also needed 4 new NPT to AN fittings.

 

--------------------------------------------------------------------------------

 

I am using Permatex Pipe Joint Compound to seal my NPT fittings.

Link to Permatex Site Info

 

 

 

----------------------------------------------------------------------------

 

In case I didn't note it before I am using Super Soundproofing to insulate the aircraft. 

This material is excellent for reducing noise levels in all types of certificated and home built aircraft. It is a closed cell vinyl insulating material which will not absorb water or oil. Has fire retardant qualities and meets FAR 25.853a Appendix F, Pt1. It is smooth on one side for easy attachment to the inside cabin skins, sides, top and front firewall.

Excellent for helicopters as well. Furnished in bulk 48" wide sheet, it is easily cut by scissors and attached with contact cement. Available in black only.

Complimentary Accessory: "How to Soundproof Light Aircraft" Supplement. To order this, simply add part number 09-42755 to your order.

 

------------------------------------------------------------------------------------

 

 

I technically haven't ordered this part yet, but will be soon. This is the Fuel Boost Pump Module from EFII. It includes two fuel filters.





 

The EFII Boost Pump Module (BPM) is the only product in its category that is professionally
engineered for maximum performance and reliability. The BPM delivers the lowest suction loss,
most stable pressure regulation, and highest quality components of any boost pump product
currently available.

The EFII Boost Pump Module also brings a new level of installation simplicity
and functionality to the fuel system of your aircraft. The BPM reduces a time consuming and
frustrating plumbing job to a simple and clean, easy to set up installation.
The Boost Pump Module is used to supply a steady source of 30PSI fuel to your engine
during take-off, landing, priming, or emergency situations. The BPM has integral back
flow prevention and pressure regulation valving.