Tail Wiring
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| Cable runs at rear off fuselage |
In reading the notes for the rear tail light an additional core to allow a strobe function was missed and it was decided to add this feature. This required two [2] 20 gauge core to be added and the existing 18 gauge core to be removed, this simple task took 3 solid hours - why?
The cable was installed in the fuselage, fixed and all work had to be preformed at the rear from a floor trolley and from bulkhead to bulkhead on the fuselage side. It only reinforces my opinion that wiring is not a job to be done when the construction ends for a whole heap of reasons but the best is the bulk time it adds to the task.
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| Cable runs starboard side longeron |
The loom tubes were installed in the starboard upper longeron, these were secured with self adhesive pads and cable ties. To ensure that all was to be safe when the cover is fitted and all access lost, foam pads were fitted and secured with cable ties [removed when cover was installed].
The pads apply light pressure to the loom tubes holding them in their correct location when the skin is installed.
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| Fourth loom tube |
Three tubes filled the available area in the longeron so the cables to the tail was added as a internal fourth run fixed to the inside of the fuselage. The tube was fixed with 10 mm nylon clamps fixed by M3 x 9.6 mm pop rivets and washers to ensure the pop rivet fully expanded.
Two plug's were installed at the rear to allow the fin and elevators to be electrically disconnected for painting or heavy maintenance.
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| Trial Assembly of starboard covers [note inlet for cockpit air] |
With the wiring complete and side covers clecoed on the next task was to install the roll bar. This had been previously trial fitted and upper mounting holes drilled in the longeron. There were no issues found with the lower factory mounting holes in the fuselage and were fixed with AN3-6A bolts with area washers installed on the inside face of the upper longeron to provide increased rip out strength.
A tapered packer was required at the port side between the upper roll bar mount and top longeron to fill a gap between the upper mount on the roll bar and longeron.
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| Roll bar installed |
With the roll bar installed the side panels can be fixed to the fuselage using the factory drilled holes. The bolt heads were located to the inside to allow ongoing inspection.
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| Port Side Roll Bar attachment Information on this co-pilot air system - click here |
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| Rear hinge |
Canopy Hinges
Additional rivets were added to both the front and rear hinges as noted on photos supplied of the current factory aircraft. The location of the initial hole was covered in a previous blog - Part 2.
A packer was installed to match the skin mounting angle to prevent distortion of the longeron flange.
Two new 4 mm holes were added and secured with aluminium rivets.
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| Front hinge |
Note: Drilling the stainless steel bracket requiring WD40 and a [sharp] 2 mm pilot drill then enlarged to 3.5 then 4 mm. All holes drilled using a battery drill to avoid burning the drill tip.
The front hinge was secured using the single hole drilled at installation [Click link above]
A stainless steel 4 mm pop rivet was used to provide improved rip out resistance over an aluminium rivet.
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| Packers |
Packers
Packers were installed between the side skins and the firewall to improve the profile of the assembly when riveted.
This was done on both sides with the port requiring a larger packer set
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