Tonight I started on the left-hand side wiring harness, and was able to run the wiring through to the stick. Hopefully I can get close to finishing tomorrow, although it might take another day or so. In addition to the headset jacks, the flap motor and baggage compartment light wiring needs to be installed before it’s done.
Fuselage wiring harness
Tonight I finished installing the right hand side harness. I drilled holes for the headset jacks, installed them, and then installed the 12v power socket and aux audio plug.
The headset jacks need to be isolated from the airframe, so I measured and enlarged one of the two holes to fit the spacer washer. Then I located and enlarged a new hole for the LEMO jack, and installed all of the jacks on the right hand side. I covered the ports with electrical tape to prevent debris from building up.
With that done, I moved to the 12v power port and headset jack. The 12v socket installed easily, and I had that installed quickly. The aux audio port was wired for a molex plug, but the small pins were very annoying to work with. I decided to use d-sub pins and sockets to connect the port, and that worked out much better. If the port ever needed to be replaced, the heatshrink can be carefully sliced open, and the pins separated.
Fuselage Wiring Harness
Tonight I started installing the WH-00125 fuselage wiring harness. Avionics Systems are building my panel, and shipped me the wiring harnesses. There are standard harnesses with a couple of modifications, one for the FlyELD lights, and the other for a baggage compartment light.
The install is straightforward. Because all of the connectors are already wired up, I can route the cables, then cut slots in the bushings so I can slip them over the wire bundle, and insert into the ribs and bulkheads.
I didn’t get a picture, but I was able to complete most of the right hand side wiring hardness install. I still need to locate and drill a hole for the LEMO headset port, and wire up the aux-audio and 12-volt power port.
Canopy Release
On Friday last week I started the remote canopy release modification, and I wrapped it up last night.
The original canopy release mechanism has a handle in the middle of the panel, towards the top. The handle is one end of a steel rod, and the other end is connected to a lever that sits behind the sun-panel. That lever drives a simple mechanism that extends and retracts the canopy hinge pins.
The downside of this approach is the loss of usable space on the panel. So Vans created a modification to relocate the handle. By using a cable instead of a steel tube, the handle can be placed anywhere. The recommended location is forward of the fuel selector valve, in a recessed area.
The modification was quite straight forward, and over several evening sessions I was able to wrap it up. I’ll have to remove the covers again so I can install the fuselage wiring harness, but that should be an issue.
Seals
Last night and tonight I installed the remaining canopy seals. I decided to remove the canopy from the plane so I could get better access, and that made the job much easier.
Canopy seals
Tonight I installed one of the canopy seals and cut others to shape. The seal went in surprisingly easily, and I was able to torque up the final 20-odd nuts securing the canopy along the aft edge.
Fairing sanding
Tonight I feathered the forward edge of the canopy fairing down to the aluminum skin. I decided to leave this where it is for now, and have Dad check it out when he visits in July.
I moved on and installed the canopy unsafe micro switch, and the avionics fans on the glare-shield. None of these are wired up yet, I’ll get to that later.
