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Flying Legend Tucano-R at Rylstone Tucano build now MeWe - Gary Spencer Salt
Monday 30 October 2017
Tie Down
This blog covers the aircraft tie down method
Overview
This aircraft cannot afford to carry 3.5 kg of tie-down's, a search located the "Orange Screw" at 125 grams each that would seem to fill the bill. The plastic tube acts as a handle while providing a cover for any dirt when stored in the aircraft.
Comments
Light weight
Overview
This aircraft cannot afford to carry 3.5 kg of tie-down's, a search located the "Orange Screw" at 125 grams each that would seem to fill the bill. The plastic tube acts as a handle while providing a cover for any dirt when stored in the aircraft.
Comments
Light weight
Wednesday 11 October 2017
Hydraulic Pump
This blog covers the work to convert the No 2 baggage compartment to a battery / hydraulic compartment.
Overview
The compartment was added in a previous blog along with the relocation of the hydraulic pump and battery.
Why? - After a series of analyses using the factory cog calculator a 2.5 kg bar was still required at the fin post to achieve a 18.0% minimum cog. This achieved a total weight saving of 1.5 kg over the standard factory battery but I had to live with a bar in the bum - unacceptable.
Installation
The mounts for the battery / hydraulic pump were folded from 0.030'' 2024-T3 sheet into channels. These were mounted to the stringers with 30 x 30 angles folded from the same material and fixed using four [4] four 3.2 mm pop rivets. The channels were then prepared to accept either the battery or the hydraulic pump and then fixed to the angles with 3.2 mm pop rivets.
To preserve access to the inside of the aircraft the center tray was fabricated from 0.5 mm aluminium sheet and fixed to the channels using three [3] M5 screws on each side engaging with rivet nuts fixed into the channels sides and will be used to carry tie downs etc when in service.
A set of straps will be added to the center tray to restrain any load placed in that area.
Comment
Very happy with the final location and no it will not move again - promice.
Overview
The compartment was added in a previous blog along with the relocation of the hydraulic pump and battery.
Why? - After a series of analyses using the factory cog calculator a 2.5 kg bar was still required at the fin post to achieve a 18.0% minimum cog. This achieved a total weight saving of 1.5 kg over the standard factory battery but I had to live with a bar in the bum - unacceptable.
 |
| Current Weight & Balance full tanks Empty tanks move the cog to 18.4% MAC |
Installation
The mounts for the battery / hydraulic pump were folded from 0.030'' 2024-T3 sheet into channels. These were mounted to the stringers with 30 x 30 angles folded from the same material and fixed using four [4] four 3.2 mm pop rivets. The channels were then prepared to accept either the battery or the hydraulic pump and then fixed to the angles with 3.2 mm pop rivets.
 |
| Fuse link located on the underside to preserve space in the tray in case I have to use a different battery. Positive and negative studs are the same as used on the firewall and remove the need to bend the battery cable through 90 degrees |
To preserve access to the inside of the aircraft the center tray was fabricated from 0.5 mm aluminium sheet and fixed to the channels using three [3] M5 screws on each side engaging with rivet nuts fixed into the channels sides and will be used to carry tie downs etc when in service.
 |
| Center tray used to store tie downs etc |
A set of straps will be added to the center tray to restrain any load placed in that area.
Comment
Very happy with the final location and no it will not move again - promice.
Tuesday 10 October 2017
Master Circuit
This blog cover the master circuit and hardware used.
Overview
To save weight an alternative solenoid was sourced based on a recommendations found on the Matronics site.
Each of the three [3] circuits has a separate bus supplied to a switch/breakers rated to meet the total demand of each circuit they supply.
Installation
To facilitate maintenance and installation it was decided to install a series off AMP plugs at the circuit breaker panel and the airframe. The plugs were terminated behind the panel on the starboard side into plugs on a dedicated bracket.
This allows the manufacture of the circuit breaker/switch panel as one assembly on the workbench and then installed into the air-frame.
Note: AMP plugs feature gold plated pins for increased reliability. The 14 guage were a push and required a little more care to achieve a satisfactory connection.
The input from the manual isolator switch was run in 6 gauge wire to the master relay with the panel 15 amp switch/breaker feed with individual 14 gauge wires and the 10 amp switch/breaker supplied with a 16 gauge feeder.
Each run was terminated onto their respective breakers using the screw connections supplied.
The main feed to the through the breaker was run in 6 gauge aluminum / copper clad cable for increased margin. The cable ends were fitted with nipples behind the panel to prevent accidental shorts when servicing that area.
Note: Battery fuse is 50 amps / Generator 30 amps
Batteries
Two [2] LifePo4 each with 20 amp hour [lead equivalent] and 230 CCA were installed into the rear compartment to achieve a 18%MAC - it not moving again that is a guarantee.
The MAC is at 18.5% empty with the relocated pump. The current battery's combined with relocating the hydraulic pump saved me 4kg [8.8 lbs] compared to the current battery. Since the original selection of batteries, EarthX in the USA have release a superior battery and the existing batteries may be replace by these at some point.
At the positive terminal a 125 amp lo-Blo® fuse was installed to eliminate nuisance blowing during temporary, short duration overloads. These are commonly used for battery and alternator connections and other heavy gauge cables requiring high current protection in automobiles.
The connection to the positive stud was made using a rigid bus to save space and weight.
The existing cables were then run to the underside of the folded channel and terminated with the same studs used at the firewall as the aluminium cable used is light but stiff.
From the studs colour coded battery cables were manufactured from flexible battery cable connecting the battery to the aluminium cable allowing ease off battery removal and preventing any chance confusion at reinstallation.
Circuit Fuses
Two holders that accept automotive maxi fuses were installed on the firewall to protect the supply to the breaker panel and the generator rated at 50 / 20 amps respectively.
The holders were fitted into a folded 0.030'' aluminium channel as it proved impractical to mount with the single bolt mount provided. Both channels were riveted to the firewall and then the holder bolted with a cap hd screw into a M4 rivet nut.
Isolator
It was originally intended to use a manual switch as a isolator without a master solenoid but this has proved impractical. The manual isolator is now a TRUE isolator in the automotive sence - pull cord - ALL power is removed.
In any track car the crews must have a means to shut the whole car down and that task is performed by these mechanical isolators.
In my aircraft in a rapid emergency where there is no time to clean up all the separate panels created - Pull the red ring.
Comment
Worked as planned.
The isolator will require a mechanical pump to work 100% as planned - watch this space - the motor is going to the shop to be upgraded and the final configuration will be decided once were verify a few items on a test stand.
This blog was not intended to give a running description of the day by day work - refer to Facebook Gary Spencer Salt for more frequent general updates.
Overview
To save weight an alternative solenoid was sourced based on a recommendations found on the Matronics site.Each of the three [3] circuits has a separate bus supplied to a switch/breakers rated to meet the total demand of each circuit they supply.
Installation
To facilitate maintenance and installation it was decided to install a series off AMP plugs at the circuit breaker panel and the airframe. The plugs were terminated behind the panel on the starboard side into plugs on a dedicated bracket. This allows the manufacture of the circuit breaker/switch panel as one assembly on the workbench and then installed into the air-frame.
Note: AMP plugs feature gold plated pins for increased reliability. The 14 guage were a push and required a little more care to achieve a satisfactory connection.
The input from the manual isolator switch was run in 6 gauge wire to the master relay with the panel 15 amp switch/breaker feed with individual 14 gauge wires and the 10 amp switch/breaker supplied with a 16 gauge feeder.
Each run was terminated onto their respective breakers using the screw connections supplied.
The main feed to the through the breaker was run in 6 gauge aluminum / copper clad cable for increased margin. The cable ends were fitted with nipples behind the panel to prevent accidental shorts when servicing that area.
Note: Battery fuse is 50 amps / Generator 30 amps
 |
| Load check wire selection |
Schematic - Master-20
Batteries
Two [2] LifePo4 each with 20 amp hour [lead equivalent] and 230 CCA were installed into the rear compartment to achieve a 18%MAC - it not moving again that is a guarantee.
The MAC is at 18.5% empty with the relocated pump. The current battery's combined with relocating the hydraulic pump saved me 4kg [8.8 lbs] compared to the current battery. Since the original selection of batteries, EarthX in the USA have release a superior battery and the existing batteries may be replace by these at some point.
At the positive terminal a 125 amp lo-Blo® fuse was installed to eliminate nuisance blowing during temporary, short duration overloads. These are commonly used for battery and alternator connections and other heavy gauge cables requiring high current protection in automobiles. The connection to the positive stud was made using a rigid bus to save space and weight.
The existing cables were then run to the underside of the folded channel and terminated with the same studs used at the firewall as the aluminium cable used is light but stiff.From the studs colour coded battery cables were manufactured from flexible battery cable connecting the battery to the aluminium cable allowing ease off battery removal and preventing any chance confusion at reinstallation.
Circuit Fuses
Two holders that accept automotive maxi fuses were installed on the firewall to protect the supply to the breaker panel and the generator rated at 50 / 20 amps respectively. The holders were fitted into a folded 0.030'' aluminium channel as it proved impractical to mount with the single bolt mount provided. Both channels were riveted to the firewall and then the holder bolted with a cap hd screw into a M4 rivet nut.
 |
| The lug at the rear was designed to engage into a guide on the original application requiring a custom bracket mount However they were light/compact when installed |
IsolatorIt was originally intended to use a manual switch as a isolator without a master solenoid but this has proved impractical. The manual isolator is now a TRUE isolator in the automotive sence - pull cord - ALL power is removed.
In any track car the crews must have a means to shut the whole car down and that task is performed by these mechanical isolators.
In my aircraft in a rapid emergency where there is no time to clean up all the separate panels created - Pull the red ring.
Comment
Worked as planned.
The isolator will require a mechanical pump to work 100% as planned - watch this space - the motor is going to the shop to be upgraded and the final configuration will be decided once were verify a few items on a test stand.
This blog was not intended to give a running description of the day by day work - refer to Facebook Gary Spencer Salt for more frequent general updates.
Breaker Panel
This blog covers the construction of the switch and breaker panel.
Overview
The panel is located on the starboard side of the pilot's seat screwed to the bulkhead. Its was decided that the panel was to be removable to allow construction and maintenance to be undertaken on a bench.
To achieve this the panel has to be equipped with a number of plugs to allow the connection of the panel into the airframe wiring.
Installation.
The panel was folded from 0.030'' 2024-T3 sheet and fixed to the fuselage former's using M4 rivet nuts three [3] per side and fixed using M4 aluminium screws. The removable panels were manufactured from the same material and fixed using M3 x 10 cap HD S/S screws and rivet nuts.
With the final layout decided for the switches and breakers the removal panels were primed and drilled using a step drill to suit either the switches / breakers as required.
It was decided to connect the panel to the fuselage wiring using AMP plugs as outlined in the blog on the master circuit. The three [3] circuits were connected via switched circuit breakers using 14 and 16 gauge wire terminated onto the master bus behind the firewall.
Use of the three separate feeds allowed reduced the wire sizes so they could be handled using the AMP pins.
One of the really big problems converting schematics into the physical without drawing the whole exercise requires a lot of imagination to be used, this saves time but leads to more work and things not happening the way you imagined.
The circuit logic was visualized as shown below with switched breakers providing power to a circuit breaker panel and to fuses behind the main panel but during installation a simpler system evolved making the use of the switched breakers of less importance - Streaker's defence is invoked.
Switched breakers will allow grouped shutdown of the selected electrical load in the event of an alternator failure but adds to the overall complexity.
Klixon 2TC2 breakers were selected for their light weight and small size especially in depth as the panel as constructed is shallow. The breakers are organized into three [3] buses - Essential/Avionics/General paralleled with terminal strips [bus's] located behind the panel.
The largest single load is the lighting especially the strobes even with all lights beign lightweight / low current LED types followed by the avionics. The other loads are mostly intermittent high current so battery storage is important as the load analysis shows the alternator lacks the reserve's to power theses.
Comment
The question could be posed - Why all this effort? - Well the builder could try and give lots of reasons but in the end its all about the vibe and a good replica creates a vibe - does it not?
This blog was not intended to give a running description of the day by day work - refer to Facebook Gary Spencer Salt for more frequent general updates.
Overview
The panel is located on the starboard side of the pilot's seat screwed to the bulkhead. Its was decided that the panel was to be removable to allow construction and maintenance to be undertaken on a bench.
To achieve this the panel has to be equipped with a number of plugs to allow the connection of the panel into the airframe wiring.
Installation.
The panel was folded from 0.030'' 2024-T3 sheet and fixed to the fuselage former's using M4 rivet nuts three [3] per side and fixed using M4 aluminium screws. The removable panels were manufactured from the same material and fixed using M3 x 10 cap HD S/S screws and rivet nuts.
With the final layout decided for the switches and breakers the removal panels were primed and drilled using a step drill to suit either the switches / breakers as required.
It was decided to connect the panel to the fuselage wiring using AMP plugs as outlined in the blog on the master circuit. The three [3] circuits were connected via switched circuit breakers using 14 and 16 gauge wire terminated onto the master bus behind the firewall.
Use of the three separate feeds allowed reduced the wire sizes so they could be handled using the AMP pins.
 |
| Switch - Breaker Panel |
One of the really big problems converting schematics into the physical without drawing the whole exercise requires a lot of imagination to be used, this saves time but leads to more work and things not happening the way you imagined.
The circuit logic was visualized as shown below with switched breakers providing power to a circuit breaker panel and to fuses behind the main panel but during installation a simpler system evolved making the use of the switched breakers of less importance - Streaker's defence is invoked.
Switched breakers will allow grouped shutdown of the selected electrical load in the event of an alternator failure but adds to the overall complexity.
Klixon 2TC2 breakers were selected for their light weight and small size especially in depth as the panel as constructed is shallow. The breakers are organized into three [3] buses - Essential/Avionics/General paralleled with terminal strips [bus's] located behind the panel.
 |
| Breaker panel |
 |
| Current Load Analysis |
Comment
The question could be posed - Why all this effort? - Well the builder could try and give lots of reasons but in the end its all about the vibe and a good replica creates a vibe - does it not?
This blog was not intended to give a running description of the day by day work - refer to Facebook Gary Spencer Salt for more frequent general updates.
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