Regulator

This blog covers the Silent Hektik voltage regulator to be used in this aircraft.

Overview
After following a number of blogs the Rotax regulator does have a checkered history leading to a number of RV builders have installed the Silent Hektik offering a more robust structure.

Note: See link to Dog Aviation installation and reasons that I agree with.

Installation

Wiring diagram
Note: Different to the standard Rotax setup

Note: The installation does require different wiring of the regulator compared to the Rotax regulator and air cooling is mandatory

ANLASSER = STARTER
BORDNETZ = ONBOARD SUPPLY [POSITIVE/NEGATIVE STUD]
GENERATORLAMPE = GENERATOR LIGHT
LIMA = GENERATOR
KONDENS = CAPACITOR
HAUPTSCHALTER = MASTER [MAINTENANCE]
ZUNDSCHLOSS = IGNITION LOCK
KONTROLLAMPE = CONTROLLING LAMP
BATTERIE PLUS = BATTERY POSITIVE
R = POSITIVE
LICHTMASCHINE = LIGHTING MACHINE AKA GENERATOR

The regulator was positioned on the center of the firewall in line with the air inlet of the intercooler to allow cooling air to bleed off the regulator.  

Two [2] M4 S/S rivet nuts were installed from match drilled holes and the regulator fixed using M4 x 16 S/S screws secured with thread lock.

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This is an early photo from late 2016 that shows the regulator clearly with wiring now underway

Headset Sockets

This blog covers the installation of the headset  plug points.

Overview
With diminishing real estate in the cockpit there was no place to install the headset plug points. Locating them on the port side would be a pain as it required crossing over the leads to exit.

Inspiration was found in the prototype when a box was noted on the side of the canopy and it was realized that headset leads plugged in here could be simply hung up at exit.

Shorts Tucano T1
Note box ringed in white

A pair of plastic jiffy boxes were selected from Jaycar and installed onto the side frame using four [4]  #6 x 12mm S/S self tappers to allow removal for painting.

The two sockets were installed on the front cover and interconnected using multi core cable fitted through 10 mm loom tube via the grommets in the image below.

Jiffy boxes ready for cable installation

Note: One advantage of the plastic boxes is they create a floating earth required by the jacks without the need to use insulated inserts

Next the existing side panel was drilled and profiled to allow a RS232 9 pin socket to fit through with the cable connecting the radio with the headset and intercom. The plug cover was fabricated from scrap 0.040'' 2024-T3 aluminium sheet fixed with M3 screws and rivet nuts onto the factory side cover.

Pilots connection point and plug entrance
Hole required bell mouthing to clear plug

Co-pilots connection points
Loom tube will be clipped to the frame after painting

Comment
Why do this in the middle of wiring - well it create's all the necessary fixed wiring points required to complete the cable connections.

A final shot of the cockpit - it's a rough mock up but I hope you can see a cockpit that creates a military feel and not just another GA cockpit and yes, it's so 1980's !

The box on top is the get-out-of-jail card if the compass is unhappy in the panel
So far its looks happy but it will be interesting when the power is applied
and we try to swing it.

Sub Panels

This blog cover the construction of the lower panels.

Overview
The lower panel has three [3] separate panels for the undercarriage, fuel pressure and belly tanks creating sub panels including all gauges and breakers. One feature that was decided on was that each panel would be plugged into the electrical system like the main panel to allow simpler maintenance by removing to a bench for servicing or creating access to other items.

Installation
The front panel was fabricated from 0.040'' 2024-T3 aluminium sheet with the plug mounts fabricated from the same material in 0.030''. All components were alodined and the front will have a suitable vinyl label applied once the final configuration is confirmed. The various brackets are fixed using the components and automotive trim tape.

All plugs are either 9 pin RS232 or AMP plugs featuring gold plated pins and sockets with both having some means of positive locking. The lower RS232 is a two [2] pin plug with gold plated pins ment for the high power music market.

The gear panel features push to test indicator lights, separate circuit breakers for the pump and control. Currently the switch is a dummy until a gear selector switch is sourced.

Rear of Gear Panel

Gear Panel

The gear panel features a fuel pressure  and differential pressure gauge along with circuit breaker for pump and control. A feature of this aircraft will be the installation of a mechanical fuel pump that can supply the fuel and pressure required for a supercharged engine. This will be outlined in later blogs as the engineering is yet to be completed. 

The reason is to remove the electrical load and dependence on the battery to keep the aircraft running in a worst case scenario. The gauges will allow the settings and pump to be monitored with the performance of the boost pump as part of the preflight checks as undertaken with a Lycoming engine.

Fuel panel

Rear of fuel panel

Mock up - yes they will line at final assembly up but this required a lot of
careful filing of mounting holes

Comments
The big error made was to fabricate the panels as separate items as alignment has proved to be a challenge. Doing it again the panels would be fabricated as a single panel with the mounting holes match drilled into the lower panel and then the panels separated.

The wiring goes on and on and on.

Leaving for a holiday and will be visiting the factory to finalize a few decisions and to undertake a few hours of flying to get a feel of the aircraft.

Canopy Breaker

This blog cover the selection and installation of canopy breakers

Overview
One of the issues that any canopy aircraft has regardless of how it is opened is it can trap the occupants in a rollover. The military have used canopy breakers since the introduction of this canopy type.

Again RV builders provide a solution.

Installation
The two canopy breakers were fixed to the canopy frame on the port side using the brackets supplied with #6 x 20 mm S/S self tapping screws. 

When finally installed after painting a copper wire tie will be installed over the hammer end locating tab just to make sure that it cannot escape in operation.

Pilots Canopy Breaker

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Hope to never use it