Christmas 2022

 

Well, here we are another Year and still on the work site. While I can be frustrated with the last 18 months, I have to thank God I am still alive to work and enjoy life and family. While this has been a lost time, it has made me put things in order and appreciate what I have, family, friends and sunny days when they are there.

I have been thrust back into doing the wiring and am inching forward. Some circuits are tested and working, while many I have tested to complete or gain the courage to apply the voltage. The Vlogs will be coming next year with useful tips and, if not, something to chuckle over.

This aircraft has been a learning experience and one of the most intense in my life. While showing some of my strengths, it has exposed many weaknesses for me to overcome.

The wiring has reached the point where the runs have to be organized, and that is as welcoming a thought as tidying up a pit of black mating vipers, but someone has to thrust his hand into that pit.

God Bless, Merry Christmas and a Happy New Year

I took a few photos just before I left. 

Pity me.

Paper Work, never-ending but it helps

Vlog #13

This is a general overview of the wiring status at this stage, with details on preparing the wiring for the throttle handle with a propeller and frequency flip for the radio available.

Vlog #12

 This Vlog covers the installation and user-adjustable flasher supplied by Custom LED to allow up to 10 selectable flash patterns.

The bracket was printed using ABS-PET plastic, filled and then sanded with 100 then 400 grit aluminium open-cut paper to achieve a smooth finish; then, 3 coats of acrylic polar White were applied to achieve a reasonable finish.

The unit is secured using M3/M4 S/S screws fitted to brass inserts installed into the plastic mounting block. 

Comment:  All the brass inserts had to be chased out using an appropriate tap to ensure smooth assembly.

When assembled finally, star washers are installed under the needs of the screws as required to secure them in place.

A pair of relays had to be used to simulate the off-on-on operation of an AN3021-13 switch that proved impossible to source, adding to the complexity but I was willing to keep my design parameters.

All in all, works well.

Vlog #11

The second of the wiring vlogs is up and covers some of the tools and techniques used up to this point. For those following the Blog, much of this is covered under the wiring tab.

Line to Blog - Click Here

Link: https://rumble.com/v1nxqv0-tucano-r-vlog-11.html

Vlog #10

 Vlog #10 is now up

https://rumble.com/v1my7jg-tucano-r-vlog-10.html

This will be the first in a series of maybe how not to, but it will be what it will be.

Vlog #9

 Vlog #9 is up on Rumble

 

Engine Induction Update

This is a short update to show where the induction is and our hope.

As you are aware, I have, in conjunction with Joe Newham, developed a new manifold to use a TBI from Rotec. This has been a side job with trying to assemble a complex aircraft, but it is approaching the pointy end of the exercise.

A manifold has been successfully printed in Ultem 9085 and is assembled to do a trial on an engine stand, see Vlog #8.

The manifold is identical to the one below, which is ABS as the 9085 is 50 cents a gram

We are as sure as one can be that this should work as the TBI now shares the same design feature with another aftermarket induction system that makes it possible, and we know that one works under boost. This will be determined soon as the engine has to go one way or another.

If it works, it will be cool......................!

Vlog #8

Repost I messed up the link

New Vlog #8 on the Tucano. This vlog covers mostly the fuel system and its features, along with and at the end, a short vid on the wing installation and undercarriage. 

It does look cool in the Battle of Britain camouflage scheme.

https://rumble.com/v1g1dl9-tucano-r-at-rylstone.html

or

click image

Vlog #7

Vlog #7 is now up on Rumble - Click on imiage.

Link: https://rumble.com/v142olc-tucano-r-vlog-7.html?mref=15uxh&mc=1nrd1

Vlog #6

In this Vlog I cover the issues of removal of the tanks on this Tucano and the scheme that I used to achieve this, part 2 will come later just before the wing installation.

Have fun

Vlog #5

Vlog #5 is now up on Rumble

 

Vlog#4

It was a week of consolidation and detailed work around the engine but at this time all the rigid and flexible lines are finished except the fuel lines too and from the pump but that is for a later time.

Click the image for the link

The paint clearing will be done rain or no rain as I have the sign-writer booked for the 13th of April. Once done the planning for wing installation will be a higher priority. At this point moving into systems and away from construction.

Josh the Avionics man will be over for a week to finish checking the electrics and in particular the engine instruments trying to have that happen before the wings are fixed on

Vlogs on Tucano

Its been a long time between posts and there are a number of reasons but the lockdown and some health issues ate all of 2021 with little progress as I was unable to be at Rylstone. When I left I had three [3] big bits in two wings and a fuselage.

The aircraft has reached a phase where the dedicated posts are not possible, they will occur as the various task is complete and there is a story to tell. So here are my humble efforts all shaky-cam with poor voice over.

These will only be posted on Rumble as I disagree with the competition.

Any questions or comments I am here.

Have fun  and click on the photos below for a link

Comment

None

Exhaust Installation

This blog covers the muffler installation after repair.

Overview
In a previous blog, the issues with the selected exhaust system were covered in detail. What I was not prepared for was the total lack of support from Akrapovic.

After the initial contact, their Australian agent forwarded my simple request for the material type to the factory. As it was manufactured from titanium, my welder wanted to know the material to allow the most suitable filler rod to be used - simple, eh! - no!

My request was greeted with a weasel-worded corporate reply or "We don't want to know."

"Project for Rotax 912 has been concluded directly with the producer. And therefore the nature of the project as well all related conditions of the product, as well as agreements with a partner, are strictly confidential, and we are not allowed to share any info. And since the product is used in particular conditions, my high recommendation would be to contact the seller of your product directly and place the question to them directly.

I apologise that we cannot give you the information you need.

I thank you for your understanding of the situation."

Milan Hernaus

Aftermarket Country Manager 

Repair

The builder decided that the most likely material was Grade 2 Titanium due to the amount of fabrication with a Grade 2 filler rod was purchased. Peter Goard welded the muffler after modifying the internal pipes to the specification outlined in a previous blog.

Poor support..!

Installation

The modified exhaust system was fitted to the engine fresh from a Marwen zero time rebuild and installed onto the engine.

As seen in the attached photo, it meets my specification allowing the radiator and oil cooler to be installed as planned.

For detail of the installation follow the link to my Vlog

https://rumble.com/vw44ju-tucano-r-at-rylstone-vlog-.html

Comment

If it all goes well in service, I will then be happy.