Mirrors

This blog covers the installation of the two mirror to mimic the prototype

Overview
All Tucanos feature two rear view mirrors mounted on the dash panel and to mimic these a couple of cheap aftermarket mirrors were located on EBay and purchased on a maybe.

Manufacture
Both mirror's featured fake chrome on plastic and that had to go, so the glass was masked and the body's rubbed back with 320 aluminium open cut. After cleaning, a light coat of plastic primer was applied along with two [2] coats of satin black. 

Tucano Cockpit

Brackets were fabricated from 50 x 50 x 3 aluminum angle x 20 mm wide, the brackets were located on the top of the panel, clearances to the canopy checked, location verified  and marked. 

Finally the mounting holes were drilled and the brackets fixed to the panel shroud. With the mirrors mounted onto the brackets and adjusted giving a clear view of the rear end - kinda of strange feeling sitting in the front seat.

Comment
Indeed they did fit

Pilot Air

This blog cover the pilots fresh air system

Overview
The pilot fresh air is delivered from two vents located in the lower panel and from overflow from the co-pilot system.

With all of the NACA ducts in the cowl allocated and not wishing to penetrate or even having the space on the firewall it was decided to look at another way to take air in from the outside. Ducts in the removable panels in the cowl were examined but the available NACA ducts were too large and would not allow a smooth connection onto the vents while most likely fouling in the instruments.

Examination of photos of the Tucano T1 showed a big blister on top of the cowl and this was an excuse to replicate it for the purpose of air supply. 

Inspiration is always there

Installation
A 3D model was created, reviewed and then sent to China for machining in ABS plastic for a number of reason with the most pressing - time.

Inlet top view
as delivered

Splitter as delivered

Splitter and cowl opening
Channel seals opening on center

Euramtec Vents

After installing a alloy channel in the cutout the splitter was installed around the center stringer then fixed from the top side of the cowl with 3 mm self tapers screws at 4 places

Openings in the to cowl into the splitter were created using a nibbler and filed to finished size. At this point the splitter was removed and painted with plastic primer then black enamel and reinstalled with a silicone sealer. 

The top air inlet was primed and painted then fixed to the cowl using four [4] x M3 countersunk screws and rivet nuts located around the flange. the face of the cover was sealed using silicone before fixing.

Completed assembly

Finally the splitter was connected to the panel air vents using lengths of 2'' OD black CAT hose fixed with nylon cable ties.

Note:  All vents were purchased with 2'' hose adaptors.

Air Inlet

Comment
The air inlet size was to suit 2'' hose but after installation I would make it about 10 - 15% smaller for a more balanced appearance.

Worked as planned and now it's something that's finished - woo-hoo !

Cockpit Faring Rear - Part 2

The Tucano require's additional air when operating in warmer environments. With the decision to add faring's at the co-pilot area it was decided to used the third panel to provide air for that area. 

A custom inlet was modeled in 3D and sent to be machined in ABS plastic in China. The cover was riveted to the side panel with 5/32'' pop rivets after cutting an opening. The size of the inlet was modeled on the air vent used on a Cessna 172 so the two should supply more than enough air to the rear cockpit. 

The factory vent is seen as a aluminium folding at the rear of the aircraft.

Cutout in side panel for air inlet

The air inlet shown feeds air into the side cover with the cover sealed at both ends against the side skin with the lower flange sealed with Raven self adhesive foam tape against the skin. A extension to the flange was riveted to the side panel to allow the seal to occur on this edge. Raven self adhesive foam tape 6 mm wide will be fitted to this edge to seal on the side panel.

Note:
The step file for the inlet cover is available to other builders - contact through the Australian Dealer Web Site - http://www.flyinglegend.com.au

Air control system behind panel

Air is directed and controlled by the co-pilot via an adjustable vent with excess air spilling over the middle barrier which is clear of the side skin by approximately 20 mm. At the end this air is allow to exit using two [2] fixed vent which directs this air to the canopy to supply the general cockpit with fresh air. When the adjustable vent is closed all excess air vents to the general cockpit via the two [2] fixed vents. If doing it again I would move the fixed vents forward away  from the canopy latch if only for the aesthetics.

The pilot has two [2] personal vents fitted to the lower panel and will be covered in a later blog.

All material used in construction was 0.012'' 2024-T3 aluminium sheet.

Air inlet co-pilot side - typical both sides - trial fitting

Will this work as described - in theory "yes" but the proof will be in the testing which is a way off but this is why its called an experimental category and this is a personal solution.

The vents used are supplied by Euramtec from their Ebay shop. A nylon mesh luggage rack in a frame was purchased to be used as a map pocket to be covered in a blog later.

Euramtec adjustable and fixed vents

Cockpit Faring - Part 1

Fairings are supplied for the cockpit sides with their locations and arrangements shown in the fuselage manual and the final arrangement is a builder preference.  See:  Fuselage Manual page 25

Factory faring dressed up

Factory Side Panels
The cockpit covers were installed by match drilling using the angle flange attached to the external skin as a template. 
[see image below]

The  instruction's show the fairings fitted under the angle but on this aircraft they will be placed on the top side to create a tidier finish.

Trial fitted the first factory panel [Item 2] and adjusted it to fit and if required trace the outer edge profile and dressed to fit as required. 

The faring was fitted under the side panel's mounting angle and two holes are marked using a felt tip pen, drilled and clecoed in position. All other holes were marked using a 1/8'' transfer punch and drilled off aircraft. 
[see image below]

Angle fitted to drill faring
See notes above

The hinges had been fitted previously as the starboard fairing has to be trimmed around the front hinge

Fitted the second faring, adjusted until a tight fit is achieved with the first then repeat process as outlined above. 

Repeat at the opposite side.

Co-pilot Fairings - Optional
This project is attempting to create the feel the Shorts Tucano so additional panels were manufactured using 0.012'' x 2024-T3 to match the factory covers and profile line from the pilots compartment to the baggage compartment bulkhead. 

The factory advised that when operating in a hot climate's additional air for the co-pilot is required. A custom ABS plastic inlet was machined and fitted to each side side panel to collect air and feed it into the third fairing shown opposite. The air flow is controlled by the adjustable vent's with surplus air vented by two fixed outlets locate at the rear of the third panel. 

Details will be outlined in a separate post.

Flaring Tools 
A series of lighting holes influenced by the prototype were added using suitable hole saws and to stiffen the panels flaring tool's were used.

The benefit to the panels is the stiffening not weight saving, its really just eye candy but help's reduce the hippy look of the panel line chosen. 

The kit shown was purchased from Ebay from FABPARTS 2009 and all worked well on the 0.012'' and 0.020'' aluminium panels.

Another brand chosen for the 2.5'' hole but stretched the metal and buckled a panel.

A replacement die from the original supplier was purchased to finish the faring's. These tools get a personal recommendation in aluminium - they just work even on painted surfaces.

Trail Assembly Port Side