Chapter 21/23 – Wired . . .

I started out today with kind of a fun little project: assembling the engine stand that I picked up at Harbor Freight with a 20% off coupon.  As I was assembling it, a note in the instructions caught my eye: “Not for use with Aircraft” . . . hmmmm?

I also set the lengths of angled steel on the top and bottom mounts to provide an idea of how those will mount to both the engine stand and the engine mount (this angled steel was one of the pieces that Marco cut for me on his ginormous metal band cutting saw… which cut through this stuff like butter!).

I then did about 2 hours worth of spring cleaning in the shop to get it a little squared away for all the upcoming activity.

Next, although I didn’t get a pic, I mounted the right wheel pant.  I noted some trimming I’ll have to do on the wheel opening, but it’s seriously on the order of about a 1/16th of an inch.  That will get it in line with the opening dimensions spelled out by Gary Hertzler.  In addition, I took some measurements on the right wheel pant that I had already taken on the left.  The conclusion was that the wheel pants match perfectly from the gear leg forward to the front pant tip.  However, from the TE of the gear leg to the back tip of the wheel pant the right one is about 3/16″ farther aft, or maybe I should say 3/16″ longer.  No big deal and it was more of a curiosity thing than anything… I can tweak it a bit when I finish the wheel pants.

I then set my sights on mounting the 8″ prop extension to the flywheel and the engine prop flange.  It took about a half hour, a block of wood and a bunch of medium strength taps with a rubber mallet to get that sucker seated to within about 0.1″ of the flywheel. Then I very gently tightened all the bolts to get the prop extension to seat tightly against the flywheel.

Then, as per Sam’s (from Saber Manufacturing) directions, I torqued the 6 prop extension, prop flange and flywheel bolts to 50 ft-lbs each.

I then safety wired the bolts in pairs using 0.041″ stainless steel safety wire.

This is my first go at safety wiring, so if anybody out there sees anything disagreeable, please give me a shout.  I’m always open to constructive criticism.  Of course, I’ll have my EAA chapter bubbas look at the build as well.

Here’s the final shot of the installed prop extension.  Let me tell ya, the only time this thing is getting removed is when the alternator belt needs replaced! [Tomorrow I’ll test mount the prop and of course will take some pics… so I figured I would get the prop extension install out of the way today].

It was getting later in the evening, so I decided to relax and watch some TV while I played with my new toy: a ClampTite tool.  I removed and brought the fuel line and oil heat oil line with me upstairs.

Then, using the Clamptite tool (another first for me), I fire sleeved the 2 hoses.  Note that I’m using blue fire sleeve for fuel lines and black fire sleeve for oil.

As I’ve seen on Joe Caraggio’s site and others, there seems to be a requirement out there (or at least a good idea) to seal up the ends of the fire sleeve so the wool-type lining doesn’t soak up any stray oil, fuel, or what have you.  I had some of the expensive gray 3M fire barrier on hand so I decided to seal up the ends with that.

Here I’ve applied the 3M Fire Barrier to the ends of each fire sleeved hose….

However, I’m not a big fan of how the gritty, blotchy gray Hi-Temp RTV ends looked, so I cut a narrow piece of heat shrink and covered the RTV’d ends up…ahh, much better!

My final build act of the evening was to simply reinstall the hoses back onto the engine.  I definitely think the fire sleeving will work and I’m glad I went this route.

Tomorrow is picture day and my next door neighbor will be using his Uber awesome digital camera to get some nice aft end pics of my Long-EZ build.  Once that happens, my next goal will be to get the engine off the fuselage and onto the engine stand.  I’ll then drop all my engine focused shenanigans and will start on finishing up the nose and getting the canopy built.

 

Chapter 21/22/23 – Schooled . . .

Today was a day of lessons for the ‘ol Airdog here.  First off, my buddy Dave B. asked me a question on this website regarding the use of an ANL type fuse link for the SD-8 backup alternator, and if I did use one was it located aft or in the nose?  Wow, ok… probably a question I should have asked myself and a big oversight on my part.

As I see it (after Dave’s prompting) the logic flows like this: I just moved the ANL40 fuse link on the B-Lead aft because the antagonist in my view was the main 40A alternator.  I again based this off of Bob’s statement that the fuse should be closest to the offending power source.  Ok, now the SD-8 backup alternator is in the back as well, but its 30A fuse –as spelled out specifically in the Z-13/8 system architecture– must be located within 6″ of the master contactor (in the nose).  But why?  The key I discovered is identifying the potential antagonistic power source, which I had done incorrectly.

I posted this question on the AeroElectric Connection forum and almost immediately got a response: the alternators are not the main point of concern since if the wire leads from them are rated at the max current they can produce, then the wire will be safe.  However, the battery is a source of potentially hundreds of errant amps hitting the wire if it decides to go a little haywire.

Thus, I had picked the wrong villain, and as Sun Tsu says, “Know your enemy.”   I did not. This of course meant that my action to move the ANL40 fuse link aft was all for naught, and moreover, incorrect.  Lesson learned.  So, my latest diagram should be depicted as such:

And my new configuration for the ANL40 is nothing more than my previous CORRECT depiction, shown here.   Ahh, the circle of life…. ha!  I haven’t yet moved the ANL40 fuse link, but I will be leaving the mounting pad on the face of the firewall in the hell hole until I know for certain that nothing else needs to get mounted in there.

In a subsequent discussion Dave and I discussed alternators going haywire, and as a point of note I’ll state that alternators such as the ones B&C sells have built-in OverVoltage protection to guard against runaway alternator current causing damage.

Moving on.

I had a lengthy discussion this afternoon with Mike Beasley, who many of you may know from his awesome website.  (Admittedly, there’s not a lot of verbiage on his site, but for the fellow Long-EZ builder the pictures on his website are a treasure trove of information).

Lesson #2 of the day for me was Mike providing me with the finer points of how he constructed his canopy.  We spoke a bit on a few other topics such as throttle and mixture cables, but the near 2-hour long conversation focused primarily on the canopy and nose build.  I am very thankful for the time that fellow Canardians take to collaborate on such tasks as this, and it really does make the build so much more manageable (and enjoyable).

While I discussed the canopy and nose build with Mike, the FedEx guy delivered my last (hopefully) round of fittings that I ordered from Summit Racing.  Again, my first choice for connecting the hose coming down from the fuel distribution spider atop the engine to the -4 AN 90° fitting on top of the fuel injection servo was the 150° hose end fitting.  And as I mentioned before, my backup was a 90° hose end fitting if the 150° hose end didn’t work out.

Quite nicely, however, the 150° hose end fitting worked like a champ!

For this fuel line, I also employed and test fitted an Adel clamp secured by the front left corner bolt where the induction air intake elbows mate together.  I think this Adel clamp position will work nicely to secure the -4 hose going to the fuel distribution spider from the top-mounted fitting on the fuel injection servo.

Here’s a bit closer view of the -4 fuel line feed to the fuel distribution spider from the fuel injection servo.

I then took a while to figure out and dial in the position and angle of my oil sump oil heat feed line that exits out of the bottom of the oil sump via a 90° steel fitting (that I calculated a 4.4″ tall standpipe will get welded to) to a firewall pass-thru fitting.  I had some angled hose end fittings on hand, but decided that to keep a nice constant curve around the RAM air box that I’d use straight hose end fittings.

I then spent a couple of hours assessing and dialing-in the flow and Adel clamp attach point for the final piece of hosing to complete the fuel line from the fuel intakes in the main strake-located fuel tanks to the cylinder fuel injector nozzles: the -6 hose from the fuel pump to the fuel injection servo.

At the fuel pump side I actually entertained the idea of cutting part of the flat flange insert at the corner of the engine mount in order to have the fuel pump out hose end fitting face outboard of the engine mount tube.  But, laying below the engine looking straight up at it, I realized that more of the hose end fitting was showing on the inboard side than the outboard side, meaning that I could get a more down angle of the hose end fitting by leaving it inboard.  So, no drilling or cutting of the engine mount flange took place.

On the fuel injection servo side, I had planned on actually running the hose aft and looping it in from the aft side to arrive at the fuel injection inlet fitting at a 0-45° angle. But then after looking at and assessing the travel of the mixture lever on the fuel injection servo, I decided to simply bring the fuel line down from the top from a slight forward-to-aft angle.

So here it is: the final fuel line piece for this entire aircraft.  Yes, of course the fuel VENT lines will still need to be run, but this does it for the actual fuel lines.

Tomorrow I’ll prep for the removal of the engine since I have the lion’s share of data that I need from having the engine mounted.  Moreover, I’ll most likely clean up the shop and take some pics of engine mounted on the fuselage before removing it.

 

Chapter 23 – Cowl me crazy!

I actually spent quite a few hours today building a lower cowling dolly that you’ll see in a number of the pics below.  I saw one of these in Walter’s hangar as we were helping remove the wings off of his Long-EZ and thought it was a good idea.  Well, although I got the dimensions from Marco, they didn’t translate over for whatever reason to my cowling and build dimensions (possibly since my fuselage isn’t loaded all the way down?).  I still used it to a degree, but I will have to mod it much further for it to really be helpful.

My goal today was to mock up the lower cowling in its close to final position (as best possible) to check the clearance between it and the engine air induction system… specifically the fuel injection servo.  To better ascertain the position of the lower cowling, I went ahead and set the top cowling in place, which I was going to do in short order anyway.

I then used duck tape to help wrangle the 2 cowling halves into some semblance of order. I’m definitely happy with the fit of the cowlings, and although Mike Melvill had an IO-360 inside of them, trust me, they are still a close fit to an IO-320 sized engine.

I taped the cowling at the top cowling-firewall interface, and was glad to confirm I have a good firewall fit, with the shape of it matching the cowling shape.

Since I had the top cowling close to its final position (I double-checked the plans, my notes, other builders’, etc. to ensure I had it close to where it needed to be…) I then made some templates to use for the cowling angle interface with the canopy and D-deck/ turtledeck assembly.

Here’s another view of my canopy-top cowling interface angle template.  Clearly I will most likely need to throw a curve into the mix as I mount the canopy, but it gives me a good starting point.

I also drew hash lines on the longerons and marked the extended angle of the top cowling contour about 18″ forward of the firewall.

Here’s my version of the lower cowling dolly.  Mine needed to be much wider front to back and much taller than the one that Walter built for his airplane.

As you can see, I removed the top cowling to better check the clearance between the bottom cowling floor and the fuel injection servo.

Here’s the best shot I could get of the fuel injection servo position inside the lower cowling. It may be hard to tell, but in this configuration there is NO clearance and the cowling is actually just touching the fuel injection servo. In fact, the very bottom nub sticking out to the right on the servo is the main fuel feed line attach fitting… clearly no room even to connect the fuel feed hose!

Very frustrated and perplexed on my no-clearance issue with my lower cowling, I took a break and grabbed something to eat.  After about an hour, with the worst case scenario of having to extend a trough under the lower cowling in my mind, I went back down to the shop to assess the clearance issue.

As I was literally sitting under the engine just looking at the layout, I came up with a very viable solution.

You see, my paradigm was that the main fuel line was coming in from the right side, and the hose coming in from the fuel distribution spider on the top of the engine was from the left.  No need to change any of that, but I did need to rethink the one thing that was really causing my clearance issues: the -4 AN 90° fitting on the top of the fuel injection servo. I had it pointed to the left as I lamented the lack of clearance between it and the bottom of the oil sump . . .

But if I moved the servo about 1/2″ forward (which I could do since I had spacers installed in between the elbows), not only did it push it forward to where the cowling was lower, but if I faced the top fitting to the RIGHT then it put the fitting right into a V-shaped channel on the bottom of the Superior cold air induction oil sump.  This allowed clearance to get the hose end fitting onto the servo outlet fitting!  Yes, I would have to spend another $20+ on yet another hose end fitting, but by doing this configuration change it gave me 2 options: A) Run the fuel distro spider hose above the fuel injection servo and in front of the air duct elbows with a 150° U-turn hose end fitting, or B) Run the fuel distro spider hose aft of the air duct elbows with a 90° hose end fitting (I’ll admit that to acquire the best solution here I bought both fittings…).

I’ll have to assess this when I get the fittings in and test these fuel line runs.  This leaves the right side main fuel feed line unaffected and it will still attach to the fuel injection servo on the right side (low).

The resulting change in my configuration will require only about a 3/16″ phenolic spacer between the lower 85° elbow and the fuel injection servo.  I will also have to replace the threaded studs on the cold air induction plenum for connecting the upper elbow to the plenum (at a minimum the lower studs, since it is virtually impossible to get a nut with so many washers on them with the current configuration).

In figuring out the final install point and configuration of the RAM air canister (not pictured here) I needed to install the 1/2″ NPT elbow on the bottom of the oil sump to assess how to route the hose from the sump to the firewall…. around the RAM air canister.  I tested a 90° hose end elbow (blue & red) but think a straight hose end may work as well.  However, since the oil heat feed line from the sump looks like it will enter the firewall on the lower left side, this will require the associated hell hole oil line to crossover from the right side oil pump fitting over to the lower forward left side of the firewall (again, crossover in the hell hole).  Not a big deal, but I will have to avoid and go above the RAM air intake expansion chamber ( . . . never-ending ripple affects!).

The bottom line is that it looks like all the components should fit, but the clearances from one component to the next are all AMAZINGLY CLOSE (but, I will note not too close to allow vibration to cause issues).

Here we have the oil drain valve with the oil heat feed 90° fitting just behind it (pic from right side of engine).

I’m fairly confident that this configuration will give me just enough of the clearance I need below the fuel injection servo and allow for all the critical air induction and underside oil sump fittings to play nicely with each other.

Of course I will have to also rotate both the fuel injection servo’s throttle and mixture levers to avoid hitting the lower cowling (I planned out the mods on those a few days ago), but again, I don’t foresee any issues with those as well.

I think with these sideline tasks taking a bit more time than I expected, my timeline for getting the engine back off the firewall and onto its stand will have to slip a day or two. Tomorrow I should be close to finishing up the firewall configuration tasks and pulling any more data I need to from the engine being mounted.

 

 

Chapter 16/23 – Air, MAPs & Elevator

I started off today by making a decision on my electrical system, one that had been nagging me a bit in the back of my mind.  The impetus for me making this decision today was a response by Bob Nuckolls on the Aeroelectric Connection forum that brought it all home for me.  In a discussion on something else related to protecting wires with fuses and circuit breakers, Bob noted: “Recall that circuit protection is for WIRES . . . and that the protective device is installed as close as practical to the SOURCE of energy that puts the wire at risk.

Thus, my ANL-40 fuse link is going back on the firewall, on the hell hole side.  I’ll most likely use a piece of 1/8″ thick x 1/2″ wide copper to connect the forward (hell hole) stud of the Blue Sea terminal to one side of the ANL-40, then run the B-lead from the ANL-40 forward to the battery contactor (however, I’m leaving the option open to use 8 AWG cable and use this connection as the location for the GRT EIS Hall Effect sensor).  This configuration will add a hair more weight aft, but puts better protection on the source of the B-Lead and cleans up my busy nose battery compartment a bit.

I didn’t mention conversations I had yesterday with both Rod Bower (RAM air unit) and Precision Airmotive (Silver Hawk fuel injection) as Marco and I were convoying in our separate trucks to his hangar.  I asked the Silver Hawk guys if I could attempt to thread the -4 AN fitting on the top of the fuel injection servo as far as it would go into the unit in order to attain as much clearance as possible with the bottom of the cold air induction plenum situated just above the fitting.  They said this would be no problem and that I wouldn’t damage anything internally/inside the fuel injection servo.

I queried Rod on some specifics about moving my RAM air box forward and mounting it directly to the aft side of the firewall, but he couldn’t picture it mentally and I ended up sending him the pic below much later after I arrived back home.

Rod got back to me today and we discussed mounting his RAM air unit with the nose of it sticking into the firewall, with about a 5.5″ gap between it and the front face of the fuel injection servo intake plate.  The requirement for this gap between the RAM air canister –which would normally mount to the front of the fuel injection servo– is twofold: 1) The RAM air canister is too wide at the aft side of it (note that it’s shaped somewhat like an Apollo capsule) and would interfere with the bottom cowling.  2) There would be no clearance for neither the oil drain valve (brass valve in pic below) nor the forward-placed sniffle valve.

To allow for enough clearance with the aft end of the RAM air canister with both the oil sump above it and the lower cowling below, I determined that it must be mounted in the clear space just forward of the oil sump.  This spot will allow the RAM air canister to be mounted an inch or so higher and still clear all the top side oil sump/cold air induction plenum and the lower cowling below . . . barely! 

[In the pic below you can see the location of my initial planned hole for a 3″ bracket (shown bottom left corner), then a piece of 3″ SCEET tubing, then the RAM air canister mounted to front face of the fuel injection servo.  Clearly, the reality of limited space and conflicting requirements for use of that space significantly changed the configuration of my air induction system.  Currently the plan is to install the nose of the RAM air canister approximately 1″ higher than the circle depicted on the firewall below].

After some discussion Rod was able to see what I was talking about and signed off on the plan.  In response to my question, he stated that he saw no ill affects in his assessment of my running a 2.5″ piece of SCEET tubing from the aft side of the RAM air canister to the front intake of the fuel injection servo (note smaller diameter than that previously planned 3″ SCEET tubing preceding the RAM air canister).

After getting Rod’s sign-off on the new air induction configuration, I then got busy mounting the Electroair MAP sensor unit on the front face of the firewall in what will be the GIB headrest/D-Deck component housing.

I marked the holes and here you can see the top 2 holes are drilled.

I then had to make some minor adjustments for hole alignment as I drilled the remaining 2 holes.

I then test fitted the MAP sensor, but will hold off on the actual screw install since I don’t have good access with the engine installed to the aft side of the firewall (the screws will get floxed in from the aft side of the firewall to the front side to create 4 screw posts… analogous to click bonds).

And another shot of the final placement of the GRT and Electroair MAP sensor units.

I then got busy assembling the new 5/8″ elevator control rod that would replace the old one that I so haphazardly decided to drill an extra hole into.  I used some larger rivets that Chris Seats gave me and got busy drilling and mashing rivets!  Here’s the assembled product.

Here you can see the internal rod that Marco lathed down the diameter of and cut to length.  We of course cut the 2 main tubing pieces to length as well.  Since I have so much real estate on the top end of the quick disconnect internal solid rod, I’m going to drill an extra #10 hole and actually install an AN3 bolt and nut in addition to the clevis pin.

Here’s a shot with the Atkinson pitch trim actuator bolt slid into the bolt hole that I drilled on this new 5/8″ elevator control rod.  Again, the internal solid rod that makes up the quick disconnect also extends down beyond the pitch trim actuator bolt hole so the hole is much more robust than on the previous elevator control rod.

And here’s a view of the other side of the pitch trim actuator connecting bolt.

Tomorrow I’ll continue to finish up engine-related tasks and will specifically focus on the final placement and configuration of the air induction components.

Chapter 21/22/23 – Configuring firewall

Today was all about getting as much of a jump as possible on the firewall configuration to get that stuff knocked out early.  I did take about half an hour to clean up all the rough edges on the wheel pants’ tire hole reinforcement layups that I did the other day, and then cut, shaped and sanded the bigger layups I did on the back of each wheel pant tire opening.

After reviewing some info on installing NPT fittings I felt I should do my due diligence and check the torque on the 45° AN6 fitting exiting the FT-60 Red Cube fuel flow meter.  It was tight, but I thought it could be tighter.  However, if you’ve seen the install manual there is explicit warnings not to over tighten a fitting on account the transducer’s case might actually crack.  In the AFP-30 Air Data Computer install manual there’s some literature on the FT-60 that states to torque the fittings to 25 ft-lbs.  Since I had a box wrench adapter on a short extension mounted to my torque wrench, I dialed the torque down to 23.5 ft-lbs to ensure I didn’t crack the FT-60 case.  Surprisingly, I was able to get one more entire revolution out of the 45° AN6 fitting… with how much pressure I had to exert to get to that 23.5 ft-lbs (again, remember I was using an protruding box wrench adapter on a short extension… both serving to add a mechanical torque advantage), I’m surprised people go further than that to crack these darn things!

Once I got the aft fitting on the FT-60 squared away, I then did some minor tweaking of the fuel filter and lines to get the filter flat again the front face of the firewall.  I then marked the position of the Adel clamp hole and the fuel line exit point on the firewall.  From inside the hell hole I drilled small holes out using my right angle drill.  I then drilled from the aft firewall side coming back into the hell hole.  You can see the drill bit in the pic below peaking through the firewall and aligned with the fuel line fitting.

Here’s a shot from the firewall side of my initial 2 holes through the firewall for mounting hell hole and firewall assemblies and pass-thrus.

I then took a #10 screw and Dremelled the head of it to create indentions for flox to better grip it.

After drilling out the fuel filter clamp screw hole and then counter sinking the hole, I then floxed the fuel filter Adel clamp mounting screw into place in the hole.  After it cures I’ll layup a small ply of glass over it.

I then took a fair amount of time to figure out exactly where to place the Electroair electronic ignition coil unit on the upper firewall.  I marked off a 1″ Demarcation Zone around the edge of the firewall to ensure I had space for both laying up the fillet glass to the upper cowling mounting overhang, plus room enough to run 1/4″ fuel vent lines as well.  I also needed to stay as far left as possible to give myself room to get the oil filter out for oil changes.

I even called Electroair and conferred with Denny on the location and orientation of the coil unit.  I played around with placing it just aft of where the CS Spar crosses in front of the firewall in the midpoint area of the firewall, and while there’s enough space in that area the spark plug wires would have funky runs to get to the spark plugs.  So, in the end I decided it had to go on the upper firewall, but at an angle.  It sits about 1/4″ above the SD-8 alternator and does very slightly impinge on the Demarcation Zone.

Here’s a closer shot of the mounting location of the Electroair EI coil pack.

I then got busy making four K1000-4 nutplate assemblies for the AN4 bolts that would be used in mounting the Electroair EI coil pack.  I cut and sanded the phenolic pieces and then riveted the nutplates to the front side of the assemblies.

Here’s an aft view of the Electroair EI coil pack K1000-4 nutplate assemblies.

Using the coil pack as a template to keep the AN4 bolts in their exact mounting configuration, I then floxed the 4 nutplate assemblies to the front of the upper firewall.

I then focused on installing the B&C Firewall/Engine ground stud and forest of tabs inside the hell hole [the usual configuration for the firewall/engine ground stud and forest of tabs is to have a forest of tabs on each side of the firewall.  However, since I only have two items that require ground on the hot side of the firewall, I forewent installing the forest of tabs on the aft side of the firewall].  Although I didn’t get a pic of it, the engine ground strap is temporarily secured on the engine side where I plan to mount it permanently, so the length I ordered for the braided engine ground strap is spot on.

On the hell hole side of the forest of tabs, I then installed the big yellow ground cable that runs the length of the firewall to the negative ground post on the battery.

I then spent the next hour or so drilling and mounting the big yellow power cable that runs from the starter contactor in the nose battery compartment to the starter through a stainless steel firewall pass-thru.  Inboard of the starter cable, I then drilled and mounted a Blue Sea connector for the Alternator’s B-lead that also heads up to the nose battery compartment.

Although this pic is a bit fuzzy, here is a final view of the firewall configuration tasks that I completed today.  From the upper left hand corner you can see a hole drilled for the Oil Heat oil return line to the engine oil sump.  Slightly lower and to the right of that is the main fuel line that feeds the engine driven fuel pump.  Towards the middle is the #10 (3/16″) screw that I floxed into the hell hole as a mounting stud for the fuel filter’s Adel clamp. Then of course is the electrical firewall pass-thru package, starting from the left with the Blue Sea fitting for the Alternator’s B-Lead, a stainless steel firewall pass-thru with the starter power cable running through it, and then the engine grounding strap that connects to the the firewall ground stud that is opposite the forest of tabs inside the hell hole.

In the pic below I added in the Alternator’s B-Lead which will be paired together with the big yellow starter cable as they both exit the engine compartment via the firewall.

Here’s a wide-angle shot of the major engine component electronics, with the big yellow power cable of the starter, the Alternator’s white B-Lead, and the connected engine grounding strap connected to the firewall ground bolt.

Here’s bit closer shot of the starter and alternator power leads.  Note that the Alternator’s B-Lead is terminated on the Alternator side but not yet at the Blue Sea firewall pass-thru. Also note that the starter lead cable is not terminated yet, and won’t be until I get the Fiberfrax and 6061 aluminum sheet affixed to the firewall.

Here’s the hell hole view of all my firewall-based shenanigans. Note that the fuel filter mounting screw is visible in-between the 2 yellow zip ties.

Here’s a little broader view specifically showing the Adel clamp that secures the pair of big yellow power cables.

Tomorrow I’ll continue my firewall configuring tasks.  I should receive some more fittings, so I’ll most likely mount some of those while I’m at it.

 

Chapter 23 – Engine mounted!

My goal today was to get the engine mounted.  Having the engine mounted for a bit will again allow me to figure out firewall component placement, firewall pass-thrus, the engine compartment hose requirements, firewall/engine electrical wiring requirements, upper cowling fitting (specifically for canopy/D-Deck angle), initial baffling requirements, lower cowling fit and air intake (fuel injection servo & RAM air) configuration.  Then I’ll remove the engine and mount it to an engine stand.

Since A) I needed to remove the engine mount from the engine to get the fuel pump OUT fitting installed, and B) do a final clean and painting of the engine mount, I decided since that since the engine mount was secured in place for the moment that I would trim down 3 of the 4 engine mount stubs to allow for clearance of the firewall face’s Fiberfrax and 6061 aluminum sheet covering.  About an 1/8″ at most getting trimmed off any of the stubs… with the top left already short enough for clearance.

I cut and placed a box that I had just received the second shipment of hoses and hose end fittings from Summit Racing (pretty much finalizing all my hose/fittings orders) over the engine mount/accessory case to protect all of it from sparks and metal debris.

Here’s a closeup of the right side engine mount stubs that needed just a hair trimmed off the front side.

I then spent about half an hour trimming them all up.

Here the right side stubs are trimmed up and filed smooth.

On my errands yesterday I picked up some hardware and some Automotive & industrial strength fast-drying White Rustoleum paint.  I spent a good 30 minutes sanding down the engine mount surfaces with 220 grit sandpaper.  Then I filed off a couple very small weld spatters that I missed before, then washed in hot water and Simple Green.  I then let it air dry.

While the engine mount air dried I spent a good 3-4 minutes shaking the can to mix up the new paint… in painting, preparation is everything, right?!  I then started spraying.  It looked good and sprayed like normal spray paint, but then about 5 minutes into painting the bottom side of the engine mount… apparently my normal spray paint decided it wanted to be a can of textured spray paint.  Within a matter of seconds I had the bottom, bottom right corner and right side of the engine mount peppered with what looked like textured, speckled paint.

Needless to say I was quite pissed.  My saving grace was that this was fast drying paint, so after about 5 minutes I felt a spot and it was what I considered in it’s green state. Another minute more and I was able to rub down the surface with a paper towel with a decent bit of force to remove the spackles of paint over nearly a third of my engine mount. That didn’t leave it feeling the smoothest, but at least the speckles were nearly completely gone. Apparently a glob of paint or something got caught in the sprayer head…. which I cleared out.  And a number of test sprays in the air to be certain, I continued on painting the engine mount.

As I waited the requisite 15 minutes for the fast drying paint on the engine mount to dry, I then preheated my kitchen oven to 175° F.  I then popped the fairly dry engine mount into the oven and baked it for 30 minutes.  My goal here on the engine mount paint is of course to have as nice as paint as possible in a reasonable amount of time, but, moreover, I want the engine mount protected against corrosion and for it to be visually inspectable for cracks (thus why no powder coating).

As the painted engine mount baked upstairs, I got to work on the engine mounted mechanical fuel pump.  I took some BEFORE pics from both the right and left sides…

I then mounted the OUT side fitting on the fuel pump, which is a 90° steel fitting that also includes a 1/8″ NPT port straight out for installing a 45° reducer fitting for the fuel pressure sensor line (on the left in pics below).  I also mocked up an AN6 90° hose end fitting (blue & red) to test out the angle for how the fuel feed to the fuel injection servo would run, and an AN4 90° hose end fitting (silver & red) for the fuel pressure sensor hose.  The aluminum AN6 hose end fitting is just to test the angle.  After I verified the angle was the best possible solution I pulled the trigger on a steel AN6 90° hose end fitting from Summit Racing (as well as a 90° 1/8″ NPT to AN3-3/16″ MAP port fitting).

I then installed the fuel pump fuel line feed IN fitting on the right side (as oriented in right pic below).

After getting the fuel line fittings squared away, and turning off the stove to let the just-baked engine mount cool, I took off for a bit to run some errands, grab some lunch, and pick up some 1/8″ thick steel angle from Home Depot for the engine mount mount that I’ll weld up for the engine stand.

Upon returning home I then grabbed the cooled and cured engine mount and proceeded to remount it back onto the engine.  [A point of note: the paint on the engine mount is about a 1 meter paint job…. it looks great unless you actually get fairly close or touch it…. if it were an external component I would probably wet sand it and hit it with one more layer of paint, or clear coat even.  Obviously it will be subject to high heat, oil, dust, dirt, etc. in the engine compartment, so I’m more concerned about a robust paint job vs. a sexy one.]

After I got the engine mount remounted to the engine, I then installed the last of the fuel pump’s fittings: the overboard vent line fitting.

Yet another shot of the fuel pump fittings.

After my airplane building credentials were called into question by a yet to be named Aussie (ok, I give . . . it was Dave Berenholtz!)  Ha!  I had to prove my mechanical prowess by actually getting the amazingly challenging cotter pins installed on the engine mount castle nuts.  Seems like it shouldn’t be that difficult, but the angles and clearances are just killer! (All in fun my friend!).

Here are the top side cotter pins installed in the engine mount bolts and castle nuts.

And the bottom left cotter pin installed.  I still have no intentions of trying to do this under cylinder #4 and will swap out that castle nut with a lock nut a bit later.

With the engine mount re-mounted on the engine and everything torqued to specs, there was nothing left to do but mount the engine!  It was go time!

So here she is . . . engine is mounted!!!

I only had minor issues with getting the last 2 bottom horizontal bolts in place on the engine mount, but after a few minutes of finagling and some light tapping they went right in.

As you can see, even with the eventual fiberfrax and aluminum sheet firewall covering, the clearances are pretty good (by Long-EZ standards) with the firewall.  The only clearance concern I have is between the fuel pump overboard vent fitting and the left aileron control tube…. I’ll have to watch that closely.

The engine looked a bit small and compact mounted to what I have so far of the fuselage, so wanted to see the cross-section of the engine…. here’s a taste of what that looks like:

Tomorrow I’ll move forward with my engine data collection tasks that I outlined at the beginning of this blog post, and any related tasks as well.  Next week I plan on starting on the nose and canopy, and hope to have all this engine stuff put to bed for a while… until final engine install crops up.

 

Chapter 16 – Control System Bearing

Since I’ve been hitting the shop hard for the last few days, today was a light on shop work, heavy on research day.  I identified over 90% of my required components to roll my own fire-sleeved engine hoses (thanks Joe Coraggio for the tip on your website!).  In fact, I pulled the trigger on the first of 3 major orders that I’ll be placing for the engine hoses.

I then checked my interior CS Spar Clickbond installation that will serve as a hardpoint for the cable management Adel clamp.  Now, I don’t mean to brag, but clearly as decent as this layup turned out (90% of it in the blind), I need to start doing these things with my eyes closed!!! Ha!

Here’s a wider angle shot that provides a general idea of the entry and exit points for the wires in the cable bundle.

And one last closeup of the mounted Adel clamp.

I then did a bunch more research, but wanted to get something curing overnight.  I had already planned on installing the CS123 control system bearing into the firewall tonight…. so, that’s what I did.  I lined up the aft end control rod with the one that runs along the fuselage sidewall, mixed up some rather wet flox, and then floxed in the CS123 bearing (this is a Cozy Girrrls product btw).

Here’s a slightly lower angle shot.  I also got up into the hell hole and added a flox fillet around the front side as well.  I don’t this thing will be going anywhere with as much flox that’s holding it into place!

Tomorrow I have just a quick couple of sideline tasks to complete and then I’ll move right into my 3-DAY BLITZ on the wheel pants!

 

Chapter 22/23 – It’s the small things….

Today’s build efforts were marked by a lot of trial & error test fits, measuring and mock-ups in an effort to get all the Hell Hole components integrated and playing nicely together in a rather small area.  If you’ve ever seen the TV show, Monk, you can get sense of my emulating Tony Shalhoub “feeling” a crime scene in my efforts to figure out placing components in the Hell Hole. Ha!

My first required piece of information before I started mixing epoxy was to figure out how I was going to route the big power cables coming from the nose: either above or below the main gear bow.  My initial thought was above the gear bow but I just couldn’t get the bend right on the big power cables to miss the sharp edge on the forward gear mount extrusion.

My test run of the big power cables below the gear bow proved much more successful in regards to not having any sharks’ teeth in the way of hard edges at the ready to gnaw through one of these big (which means important! right?!) cables.

Moreover, having to remove and install the big power cables in an Adel clamp in the access hole at the base of the GIB seat bulkhead exposed yet another potential gnawing issue on the rather sharp outboard access hole edge.  Thus, I spent a good 20 min with some Perm-A-Grit tools and my mini German hack saw to create a nice round cable-shaped edge in the corner to alleviate any future pain & suffering to my outboard positioned big yellow cable.

I also test routed the return line for my oil heat system a half dozen times to get the right position for the Adel clamp Clickbond hard point.  Not only does the Adel clamp secure the oil return line, but it will keep it pressed downward a hair to also avoid the left front mounting extrusion of the main gear.

With my Adel clamp positions –and thus my Clickbond hardpoint positions– known, I pressed forward with setting them in place with 5 min glue.  Below is the left side oil heat return line Clickbond on the left aft side of the GIB seat bulkhead.

I then glassed it with a 2″ x 2″ 3-ply BID pad….. peel plying it of course.

Here we have the oddly positioned Adel clamp Clickbond hardpoint for the 2 big power cables.  I placed it on the corner like that to best angle the cables so that they are positioned well for mounting to or traversing through the firewall.  In addition, I wanted to minimize the added depth directly below the gear bow here to just the thickness of the cables, and not add the thickness of a bulky Adel clamp.

I cheat a bit when it comes to glassing on the gear pads or gear bow and add an extra ply or two, as well as making them oversized, just to take the opportunity to add a bit more oomph to main gear strength.  Here is a 4-ply BID pad for the Clickbond that covers about 3/4 of the existing gear mount pad.

With the leftover epoxy I whipped up some thick micro and filled in some open blemishes on my brake line loops… and then peel plied the micro.

I still had just a bit of epoxy left over (I always seem to make a bit too much when I just get back into glassing after a long hiatus) so I glassed in a 2-ply BID pad that I had planned to put in around the final wire access hole that I’ll drill into the inside floor of the CS Spar.

Here’s the 2-ply BID pad after I removed the peel ply a couple hours later.  Tomorrow I’ll glass a 2-ply BID pad on the underside of the CS Spar in the same area.  When the hole gets drilled I will be digging out the surrounding foam and creating a flox hardpoint around the hole to reinforce any strength that may be lost in creating the hole.

With my shop work done for the evening I headed upstairs to do the final -6 45° AN fitting install on the FT-60 “Red Cube” Fuel Flow Transducer.  I wanted the fitting clocked more aligned to the side marked with “FF” but it was just too loose in that position. I checked to see if I had any more -6 45° AN fittings on hand, but I didn’t. So, I took it down to the Hell Hole and checked to ensure there was enough clearance with the fitting situated as it is more up than slanted straight inboard.  The clearance is fine –I’m using a 45° fitting to more easily clear the aft main gear mount– but it will mandate that I get a little more creative with my bends on the 3/8″ aluminum fuel line run to the filter.  (I also constructed 2 of the 3 connecting wires for the fuel flow meter).

Also pictured is the brass fitting that I picked up from Airflow Performance when I ordered my Sniffle Valve.  It looked as if it had a lower profile than the 90° barbed brass fitting that I had on hand for the mechanical fuel pump overboard vent port.  In comparing the two fittings, this one looks like it will be a bit more shy and protrude out about 0.15″ less than the barbed brass fitting.  Yes, not much, but when we’re talking engine to firewall clearance, every bit helps.  Since I had the Loctite 567 out, I went ahead and installed an aluminum barbed fitting into the right angled brass fitting.

Lastly, I figured I would provide a glimpse inside my “evil lair” at what I call poor man’s CAD: paper, pencil, ruler and an eraser!

My final act of the evening was to update the external aircraft lights electrical diagram. Tomorrow I’ll continue my quest to wrap up the Hell Hole configuration so I can get the firewall installed.

 

Chapter 9/22 – Bloody Hell . . . Hole!

I started off today assessing the configuration of all the hell hole components and the wires in, around and through the hell hole.  I did some research on drilling into the CS Spar, knowing that the Spar Caps were sacrosanct, but what about the other areas?  I’ll touch on this later in this post.

I then started my shop tasks today with a small repair.  Yes, hard to believe that any of the 1/8″ aluminum brake line tubing coiled up in the hell hole since 2012 would ever get a ding or scrape on it . . . well, folks, the unthinkable happened!  On my left brake line, about 6″ where it exits the lower fuselage, the tubing had a visible dent/crimp in it (circled in red in pic below).

My goal this morning was to either extricate the dent/crimp and repair the line –without destroying or mangling it– so that it would function as designed, or go with the nuclear option if need be: cut the line at this point and tie in the brake line coming from the wheel farther forward than I had planned.

By my calculations I was dealing with a 0.075″ diameter hole, and I measured a piece of hanger wire that I’d be using at 0.069″ …. Hmmm, seams like it should work (blue arrow in pic below).  I filed the tip smooth and hit it with Acetone to clean it.  But it proved just a tad too thick.  Plus, it wasn’t as arrow straight as I would prefer.

After pondering a bit, Voila!  I found the solution, pressing a perfectly straight and slightly narrower TIG welding rod into service.  I marked a point on the rod that was past the offending dent in the line, and slowing worked the rod, and aluminum tube, to get the rod though the tube and remove the pinch in the line.

Here you can see I’ve reached my mark, denoting that the 1/16″ welding rod is clearly past the offending pinch in the brake line.  I then worked the both the welding rod and tube for a good 10-15 min longer just to ensure that the dented section was as opened back up as close as possible to full diameter.

I wanted to institute some service loops for the brake lines and had some initial thoughts about using Adel clamps or some other means to keep the tubes in place.  Not only did I want to keep the aluminum brake line tubes themselves clean in the event I may need to use them for any reason in the future, but I definitely wanted to protect them as well, especially since I do plan on jamming stuff into the hell hole for storage during flights.

I tried Nylaflow but the resulting loops against the lower aft side of the GIB seat back bulkhead proved too tight for Nylaflow.  I even tried working the Nylaflow into a nice loop before placing it on the brake line, but it just kinked on me when the radius got too tight. Looking around the only thing I had on hand was the clear tubing I was using for the engine dehydrator, so I stole a couple of lengths off the line and pressed them into service.

Since the tubing will be out of the sun and under what we Canardians typically do in situations like this –bury it micro and throw a couple plies of BID on top!– I wasn’t overly concerned that it’s not “aircraft grade.”

After the protective clear tubing was in place over both brake lines, I then cleaned  up the ends of aluminum tubing and temp mounted them in their respective reducer fittings.  I then mounted the reducer fittings in their respective Adel clamps. That gave me a starting point to finalize the size and configuration of my brake service loops, which I then taped in place.

Here are Before & After pics of the right side brake line set in place and then with the service loop micro’d and glassed in place with 2-plies of BID . . . I used 2 plies to help protect the brake line against any untoward pinching.  Obviously brakes are quite a useful thing in fast landing aircraft like Long-EZs.

And here are Before & After pics of the left side brake line set in place and then with the service loop micro’d and glassed in place.

A different view of the right side brake line with the service loop micro’d and glassed in place.

Left side brake line with the service loop micro’d and glassed in place.

While the micro and BID layups cured on the brake line service loops, I took a few minutes to mark my lower engine mount extrusion bolt heads, nuts and washers with some orange torque seal.

I then set my sights on getting the wing NAV/Strobe and Wig-Wag lights wiring runs in the most unobtrusive, out-of-site way possible.  As I mentioned at the start of this post, I had done a fair amount of research both in the plans, and online, in regards to drilling holes in the CS Spar.  The results of my research was of course to stay away from the Spar Caps, no drilling through the shear web (which is actually common for the one hole required for the Autopilot roll servo, if used) and remain clear of the extrusion hard point areas.

I’m not sure exactly what #3 is all about since I have no plans on drilling INTO the hard points, but any viable hole for cable runs is going to be within 2″ of the hard points… and that is “in the area” in my book…. so of the 3 sacred “No-drill” rules I found, I’m apparently violating all the but the spar cap rule.

So, in probing around in my hell hole I discovered a spot up in each corner just aft of the CS Spar-GIB seat back intersection where there is sparse glass/flox.  It’s actually the lower angled “bull nose” of the CS Spar and that is where I placed my bullseye for drilling a 1/4″ hole diagonally/aft on each side to run my wing lighting wires from hell hole to CS Spar (or vise versa).  Here’s the result.

Might I say for my friends in the southern hemisphere: it worked a treat!

I then pulled the wiring out of the hell hole/CS Spar and took it upstairs for further processing (i.e. soldering).  I then soldered the left and right CS Spar wing NAV/Strove light wiring together along with the shielded cable run to the light switch on the panel.

I know it’s fairly difficult to see the wires, but I looped them up over my kitchen light with both sides dangling down just to get an idea of how long the wiring harness is that we’re dealing with here.  And this only gets out to the end of the CS Spar.  The internal wiring that goes through the actual wings is yet to come!

Here’s the completed wiring harness for the wingtip NAV/Strobe lights.  It’s late so I stopped on this harness, but I will also have wing tip (or outer wing let’s say) mounted landing/taxiing/wig-wag lights as well, which I still need to make up that harness for.  BTW, the left/right CS Spar portion of the wiring is on the left in the pic below, the black ground wire will tie into the “Forest of Tabs” in the hell hole, and the wire bundle on the right goes forward to the switch on the instrument panel.

Tomorrow I will continue with my Hell Hole shenanigans to the point I’m comfortable with closing up the major access to the Hell Hole by installing the Firewall.

 

Chapter 14/23 – Baffling Extrusions

Within a day of coming back from NC I started feeling a bit sluggish, and felt a cold coming on.  Well, today it hit me pretty hard, so I’ve been moving at a bit slower pace.  I’m hoping tomorrow I’ll feel well enough to get the lower engine mount extrusions glassed into place.  On top of all that, when I woke up this morning it was a virtual winter wonderland outside, with snow continuing to fall and a good few inches already on the ground.

So I grabbed a cuppa and went through Mike Beasley’s baffles and –while looking at his website– taped a number of the pieces together to get a good idea what his were all about.

The initial confusing part on his just looking at them is that all the annotated & marked sides are actually the interior side of the baffles, with the blank sides ending up what you see when you piece them together, or the exterior side.

So once I got that little tidbit down, I was able to get a good handle on what was going on.  Here’s the inside (looking aft) of the lower skirt that wraps around the alternator & starter.

Here’s the top looking aft.

Now, since I’ll have my oil cooler in the plans location on the side of the engine and not nestled in the aft underside region of the motor, I won’t need the aft lower skirt positioned like Mike’s (and countless other EZs) so far aft that it just barely covers the aft end of the alternator and starter.  Here’s Marco’s oil cooler in the plan’s location, just forward and to the left of the motor.

Here’s Mike Beasley’s real world baffles, with the lower baffle skirt far aft to account for the oil cooler placement.  If I were going to place my oil cooler in this location, I think it might have been a better, cheaper option to just use Mike’s Beasley Baffles.  From what I can tell Mike really did a bang-up job on his baffle templates, so they are certainly a viable option for most builders that are installing an O-320.

That being said, here’s a lower baffle skirt placed much farther forward that has both the alternator and starter exposed, but still has a centerline mounted oil cooler.  My baffles will look more like this, only without the oil cooler mounted in the centerline position.  So in my situation I think it will work out better having the VANs baffle kit on hand to modify.
(To be clear, I will be using Mike’s baffle temples extensively –as I have been doing– to modify the VANs baffle kit).

I then compared Mike’s baffles to the VANs, and assessed what I would need to modify on the VAN’s baffles.  On the set of side baffles (bottom of pic) you can see my proposed line cuts off that big blank piece of aluminum, which would be on the aft side.

This expanse of baffling would normally match up to the considerably wide shelf going aft of the cylinders (see 3rd pic from top, above) and which then drops down to create the skirt running across the aft faces of the alternator and starter.  Here’s another example on Mike Beasley’s bird.

Again, since my lower aft baffle skirt will be located forward of the alternator and starter, I only need a very narrow shelf just aft of the rear cylinders to then drop down to create the lower baffle skirt.  Here’s a good depiction of what I’m talking about on Buly Aliev’s Cozy, where he used the VANs baffle kit.

I then made it down to the shop to get a little bit of prep work in for installing the lower engine mount extrusions.  I copied Dave Berenholtz in bolting a wood plate to the engine mount to help easily ascertain the mounting angle of engine mount/engine during the installation of the lower extrusions.

Here’s another shot.  BTW, the plans would have you install the engine mount so that the prop is 2° higher than the front (firewall side) of the engine.  This makes sense since the Long-EZ, like many aircraft, flies about 2° nose high.  However, remember that the 2° number is based on a 118-125 HP Lycoming O-235 engine.  If you’re pushing a few more ponies, which I and most people are these days in Long-EZs, then it takes less angle to keep the nose up.  Also, 2° high on a higher powered engine probably won’t get you level flight, but a slight climb… which then of course would mandate more trim forces in play.

For example, with a planned 220 HP engine, my buddy Dave B. set his angle at 1.1°.  So for my 180-190 HP motor, I’ll be setting my engine angle around 1.4°.

In addition to fiddling about with the baffles, I also tweaked the lower engine mount extrusions install plan and will hopefully get these guys glassed in tomorrow, or the next day (depending on how I feel of course).