Firewall Forward Wiring and Plumbing

Dad and I have spent three days working on the hoses and wiring for the engine.

I would guess we are about half way done now. As usual, we are slowed a little by needing to order parts or supplies. For example, the FM-150 requires you to remove the fuel servo mounting bolts and replace them with longer ones. They thoughtfully supply the longer bolts with their servo, but want you to use Loctite 620 on the new bolts — not available locally.

So here is what we have done:

Primary Alternator, installed and wired. Minor cable management and final adjustments left.

Starter wiring is nearly complete. The primary power wire (2 gauge) is in place, terminated and torqued. The smaller wire from the starter solenoid still needs to be terminated.

FT60 Red Cube fuel flow transducer installed. Still need to do final wiring and torque hose fittings.

Fuel lines (from firewall to fuel pump, to fuel pressure sensor, to FT-60, from FT-60 to FM-150, from FM-150 to spider) partially done. Waiting on a part from Van’s Aircraft.

Oil lines (to/from cooler, to oil pressure sensor) partially done.

Secondary Alternator – done then undone. I decided to re-clock it to ensure the power lug is not too near another component. Now I need a new gasket — on its way from Spruce.

Oil cooler – shelf is installed. Oil cooler assembly is mostly done, but still on the bench down stairs. I want to get the right P-Mag installed before I put this in place.

Major things left to do:

P-Mags, lots of butt splices, propeller and propeller governor, exhaust system, firewall penetration firesleeving, more adel clamps then I care to think about.

30 hours (2 people x 15 hours).

This is the incorrect fitting that apparently comes from Lycoming. I ordered the correct one from Van’s (KB-90-T). The new fitting makes the host fit better and prevents fuel pressure values from pulsing due to a restrictor in the AN fitting to the fuel pressure sensor.
Here is the FM-150. Note that it seems to be sitting on it’s side. You have to have the IO-390 adapter kit which consists of a mounting plate for the mixture and throttle cables, new mounting bolts, a gasket, and various other parts. I am certain that the early RV-14 builders had to figure all this stuff out themselves so it’s nice to have it all in a neat package (other than the Loctite 620 that is called for).
This is the fuel flow transducer (FT-60). Note that if using the AS Flightline hose package you clock the fittings a bit differently.

It’s On the Gear

We got the main gear done. I checked the alignment and it appears that both sides toe in (that’s good) but they probably toe in to far (that’s bad). I will check them a few more times, but I suspect I will need at least one shim (@ $29 each) on each side. Some experienced guys said I can just use a washer or two, but I am going to stick to the plans and add the Van’s shim.

We then worked on the nose gear and completed that too. This had a lot of parts but was relatively easy to put together. I wasted about two hours looking for two parts prior to beginning. One (the elastomer pad) was wrapped in plastic and paper and I picked it up about a dozen times during my search without realizing that was what it was. The other was a washer that you need to trim to fit that I had right in front of my face the whole time. Because I didn’t initially realize that I had to trim it, I didn’t figure out that it was what I was looking for.

In the end, it is pretty cool to see the thing sitting on its own gear.

We will do miscellaneous work on the engine (install fittings, 2nd P-Mag, oil filter adapter etc.) and get ready to mount the engine next weekend.

The big move to the hanger is tentatively planned for July 25th.

10 hours (2 people x 5 hours).

Fixing a Mistake

I mentioned this before, but I realized that I wouldn’t be able to install two rivets near the canopy aft frame because I had already installed the canopy latch mechanism. I certainly was not looking forward to uninstalling the latch mechanism just to put in two rivets on each side. Last night, my father and I decided to do it. It probably took about 2.5 hours to uninstall, rivet and reinstall everything. Very frustrating!

Funny story, I very nearly managed to get a closed end ratcheting wrench stuck in such a way that I would not be able to get it out. I was tightening a bolt for part of the latch mechanism when I realized that the wrench on the nut side was trapped between that bolt and another nearby bolt. I couldn’t back the bolt out because my wrench would just ratchet when I turned the bolt. I yanked, pried and cursed. I seriously thought I was going to have to leave the wrench where it was forever. I finally managed to get a second skinny open end wrench on to the nut so I could back the bolt out. Man, that was close!

Lots of Deburring

Lots and lots of material preparation. Deburring the parts for the canopy mostly. Only way to describe it is “tedious”.

BTW, the interior from Lemke in Germany arrived. It looks very nice!

Things are Starting to Ship!

The Whirlwind propeller arrived today and it is beautiful. I opened the box just to look at it despite not being able to do anything with it for at least three months.

Meanwhile, I got news that the finish kit will arrive at the freight terminal next Friday. It weighs 411 lbs and is 98″ x 49″ x 30″. The shipping charges were $770.00. If I had had it delivered to the house it would have cost an additional $70. I wasn’t sure when I was going to be home so I decided to just have it shipped to the terminal and then I can rent a trailer to go get it.

The panel is still being built at SteinAir. According to Nick, the panel has been cut and painted, but the technicians still have 4 to 5 panels in front of it. Still guessing it will be mid-April.

Mistakes

I was putting in a small number of AACQ4-6 rivets to hold the plastic guides for the rudder cables. Apparently, my pop rivet tool was not tightly against the side of the tunnel and I ended up with a bad rivet. Normally, not a big deal — just take it out and put a new one in. Except I had exactly zero AACQ4-6 rivets left. Oh well, a call to Van’s to order $8 worth of rivets and a small assortment of other stuff I needed…

Moving the Project to its New Home

Yup, we decided to move it to my basement so that I could more easily work on it whenever I had some free time. The challenge was getting it into the basement. I determined that taking a window out would allow me to move it into an unused space in the basement that from this point forward will be referred to as “The Airplane Factory”.

Don’t worry, I will be able to get it out in a few months when it is ready for the engine and landing gear.

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