July 29, 2003

Today I finished up the tail strobe and position light wire run. This had been driving me freakin' nuts because there were too many choices on how to go about it. Since this is a taildragger, I've got a fat steel tailwheel spring mount in between F-711 and F-712, and I wanted to avoid drilling through it if I could help it. Well, here's what I ended up with...two relatively small holes instead of one giant one. The frickin' strobe wire is the fattest wire in the plane by far. Basically I drilled these holes so that they wouldn't penetrate the spring mount rear flange. People have told me they use snap bushings here, but I just don't get it...snap bushings are designed for a maximum bulkhead thickness of like 1/8" or so. Any thicker than that and the locking tabs can't engage...and the bushing can feel free to slide out of place. In this case, the total thickness is at least 1/4", what with the hinge bracket, the fat VS spar doubler, the VS spar itself, and then the *doubled* F-712 bulkhead. There's no good way that I could tell of locking a snap bushing in there. So, upon the advice of an RV-6 builder, who said to just freakin' drill it and move on, I chamfered (bevelled) the edges of the holes really well, and I intend to glob RTV in there as a sort of naturally molded wire cushion and anti-chafe mechanism. I chose this location because from here the wires will be able to more or less directly flop down into the bottom rudder fairing and run their merry way back to the combo tail light.

I also hadn't drilled any pass-through in F-711 yet, since I had been waiting to see how F-712 worked out. So as you can see here I drilled for an SB-500-6 snap bushing just above the forward flange on the spring mount. This shot is looking forward at F-711 through the left inspection hole.

Here's the view looking back at F-711. The wires exit the conduit at F-710 and rise up slightly to go through the snap bushing. I might have continued the conduit all the way through F-711, but remember the elevator trim wire needed to depart the bundle further forward. So it all seems to have worked out fine.

My order from McMaster-Carr came today with the 1/8" ID Tygon tubing that I ordered for the LightSpeed Plasma II ignition's manifold pressure sensor. If you recall, I had originally installed 1/4" ID tubing from the first bulkhead fitting directly to the ACS2002's manifold pressure sensor. Well, I now have the new and relocated restrictor bulkhead fitting, which is for 3/32" ID tubing. So...I gotta go from 3/32" and tee out to 1/8" ID and 1/4" ID. Kind of convoluted, but not really. I got some straight reducers, 1/8" to 3/32" (on the right), and some reducer tees with dual 1/8" and single 1/4". I say "some" because you can't order just one of these from McMaster. So if anybody out there is in a similar predicament, let me know and I'll hook you up.

UPDATE: Sorry, I'm tapped out now...go to McMaster-Carr's web site and search for polycarbonate single-barbed tube fitting. The part numbers I used were:

Here's the installed setup. First I transition with a short 1" or so section of 3/32" tubing to the reducer (or expander in this case) to 1/8", which tees out down to the ACS2002 sensor with 1/4" tubing and runs 1/8" tubing over to the left side of the front deck (via snap bushings).

And here it connects to the LSE brain box. I used RTV gobs here and there to keep the tubing from moving around.

Ok, gotta get that right brake line finished. This was a little intimidating because I wanted to use a single uninterrupted line, and I wasn't sure if I'd be able to make the bend at the firewall fitting and keep everything tidy. No problem. I ran the tubing in from the right side and made kind of a rearward spiralling bend.

Here's what I'm talking about. It's tough to tell, but that diagonal engine mount member goes right in front of the right AN fitting. I wish Van's would take a closer look at stuff like this when spec'ing out these fitting locations! If you're building your firewall, consider moving these fittings even just 1/2" or 3/4" to the left. It could have to do with the IO-360-A1B6 engine mount, since I'm guessing Van's just stole the fitting locations more or less from the RV-6 plans, which didn't support the 200hp engine. Anyway, just think about this if you haven't drilled for these fittings yet. So the tube literally has to curve down and left first, and then it can hook back to the right.

Hard to see since the flash picked up the engine mount more than anything else, but the tube runs along the firewall, about 1/2" to 3/4" away from the firewall and the engine mount. My goal is to have this run spaced appropriately and unsupported, since it will be well supported over at the top of the gear leg.

So here I've got the spool and I need to curve around the landing gear weldment and get it to the back of the leg.

It's about 3/8" away from everything. This takes a bit of phenagling to get it curved like that and standing off without contacting.

From there it's pretty simple. Straighten the tubing and run it down the leg. And integrate that half loop at the bottom. The hardest part there is determining where to make the cut, since the tubing has to be pulled away from the brake in order to flare the end. No big deal though. I just wanted to get it right since I didn't want to botch the beautiful firewall end by mis-cutting the bottom!

I safetied the brake caliper and that was that.

Next   |   Previous   |   Home

Dan Checkoway ()