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Firewall Forward 2
Baffle Installation
Trimming the Baffles
Finishing the FWF
Fabricating Spark Plug Harness
CHT & EGT Sensors
Throttle/Mixture Cables
Purge Valve Cable
FAB Construction
GPS Antenna Tray
Canopy
Wiring
Engine
Miscellaneous


Firewall Forward 2
 

Date

Description of Task   Hours
  Baffle Installation
 
 
12/6/08 I started by fabricating the support brackets and assembling the oil cooler mount at the #4 cylinder.  After drilling and clecoing, I disassembled and deburred the components.

 
3.0
12/12/08 I continued with the baffle install by carefully trimming the pieces so they would fit correctly,  I was able to get the rear, sides and the front ramps fitted.

 
4.0
12/14/08 Fiddled with the baffles some more.  I installed the Skybolt cam locks in the lower cowl and "squeezed" the lower cowl into position so I can see how much the baffles need to be trimmed.
 
2.0
12/19/08 Today I trimmed the front baffle ramps enough to fit the lower cowl.

 
2.0
12/20/08 Continued with the front ramps by fabricating the gussets and support brackets.  After drilling, I deburred and riveted the brackets to the front ramps.

 
4.0
12/21/08 I riveted the front ramps and gussets to the cylinder 1 and 3 baffles and then installed the lower cowl.  I also started "hole-filling" on the upper cowl.  Once the upper cowl is decent (at least near the rear where the camlocs will be installed), I will prime and install the camlocs.

 
3.0
  Trimming the Baffles
 
 
12/22/08 I started trimming the baffles by starting at the front and slowly moving down the sides.  I would mark 0.50" and cut it off with the Dremel.  Deburr and set the top cowl in place and repeat.  I am using a trick I learned from Bill Repucci that involves placing jumbo paper clips spaced every 4-5 inches around the baffles.  When you place the top cowl in place, you can see how far the cowl "pushes" the clips down and indicate where the baffles need to be trimmed.

 
3.0
12/28/08 Continued trimming and cutting until I had a consistent 3/8" gap all around with the top cowl in place.

I needed to stiffen the baffle area around the oil cooler due to the number of builders who report baffle cracks developing in this area.  I used 3/4" AL angle and riveted it along the rear.  Later, I will add a brace from the stiffener to an engine centerline case bolt.

 

4.0
  Finishing the FWF
 
 
1/1/09 Happy New Year!  This completes three years of construction on this plane.  I celebrated by Drilling holes on the rear baffles for installing cooling tubes for the P-Mags.  I also installed a cooling tube for the alternator off the right front inlet ramp.

I also finished securing the lower baffle seals around the #2 and #4 cylinders by using safety wire instead of the threaded rod.

I drilled the hole for the fuel purge return line in the lower right corner of the firewall.

I need to finish up some loose wiring so I started by wiring up my P-Mag and E-Mag.  I also connected the manifold pressure line to each Mag.

 

 
  Fabricating Spark Plug Harnesses
 
 
1/2/09 I started fabricating the wiring harnesses for my E-Mag and P-Mag ignitions.  You get a couple rolls of wire, some connectors and a crimping tool.  After about an hour of reading and re-reading the plans I started fitting the wires.  I also tested each wire with my OHM meter to verify good connectivity.
5.0
1/3/09 I finished the plug wires and started tidying up the engine wiring.  I used zip-ties for the spark plug wires and Adel clamps wherever I could.  I need to place an order for more clamps as well as a few other things.

 
 
  CHT & EGT Sensors
 
 
1/9/09 I picked up some Alpha Metals soldering flux today at the local Ace Hardware so I could start the EGT and CHT sensor installation.  I decided to drill the EGT sensors 2.0" below each flange due to the #3 cylinder having a welded connector which ruled-out any location between 2.25"-6.25".  I drilled each cylinder probe hole #30 and installed the probes.

I also had previously installed each CHT probe so I measured the sensor wires allowing for a "drip-loop" and crimped on the connectors.  After heat-shrinking the connectors I tied up the loops with zip ties or Adel clamps.

I also finished installing the bolts and oil line fittings for the oil cooler.
 

4.0
1/10/09 I finished connecting the EGT & CHT sensor connections on the right side today and tied up all the loose wiring.  I also tied up the wiring for the fuel flow meter.
 

Throttle and Mixture Cable Installation

I received my cables today from Van's.  I started with the throttle cable and ran it through the firewall to the quadrant in order to determine how to fabricate a bracket for attachment.

 

6.0
1/11/09 I fabricated another bracket for the purge cable that would allow attachment to two engine bolts and allow a single bolt for attaching both the purge cable and fuel line support.

 

Terry Tibbits came by today to help me pre-oil the engine.  I bought an oil pressure gauge and we were able to spin the prop using the starter until it read 40 psi.  Good enough.
 

3.0
1/16/08 Today, Jim Olson came by and helped me with a few firewall items and later on, Karl Lambert, another EAA Chapter member came over and helped me finish installing the throttle, mixture and purge valve cables.

Purge Valve Cable Install

I also installed the purge return line to the firewall bulkhead fitting.

 

6.0
1/18/09 I attached some more Adel clamps where needed.  I mostly worked on installing the wing tips.
 
1.0
  Filtered Air Box Construction
 
 
1/25/09 I need to order more epoxy so I started to work at fitting the FAB.  The first thing needed was to remove the prop in order to install the lower cowl and check the alignment of the FAB.  Initially, I needed to cut off 1.50" from the front in order to allow the cowl to drop down without hitting it.

Then, I fluted the airbox flange in order to create a slight upward slant to match the cowl inlet.  I drilled the mounting plate to the airbox and installed the filter clips and platenuts.  I also riveted the fiberglass lower portion to the top plate.  With it all together, the fit is perfect.

I then cut the hole in the bottom of the airbox for the bypass gate.  I drilled it and installed the base using RTV as a sealant.  I also drilled two #30 holes for drainage.

 

6.0
1/31/09 Today I trimmed the block and glued it to the cowl using E-6000.  Later, I carved it to match the opening in the lower cowl.  I then laid up three layers of BID to extend the opening to the FAB.

While I had the epoxy mixed, I added some flox and bonded and riveted the right wingtip upper hinge.

I safety wired the FAB plate to the throttle body.

4.0
2/6/09 I laid up three layers of glass for the cowl extension and held it in place with a balloon.
1.0
2/7/09 I trimmed the foam back and trimmed the excess glass.  I then laid up another layer of glass inside the cowl for reinforcement.

 
1.0
2/8/09 I sanded the opening smooth and added another coat of epoxy.

 
6.0
  GPS Antenna Tray
 
 
  I fabricated the Antenna tray for the three GPS antennas and the XM Radio puck.  I riveted the firewall hinge side to allow the tray to sit 3.0" below the cowl.

I also wanted to finish the top cowl so I drilled and clecoed the "elephant ear" ramps.  By placing the top cowl in place I was able to see how much to trim off the baffeling.  I then epoxied the ramps in place as well as the oil door latch cable and installed the top cowl to allow the epoxy to set with it all in place.

 

 
2/13/09 I continued working on the FAB.  I installed the Alternate Air cable by bolting a flange below the sub panel connected the cable to the air box door.

I then riveted the seal on top of the air box using RTV to seal the gaps.  On the inside of the lower cowl I used E-6000 epoxy and clamps to secure the seal.  This area is too tight to get a pop rivet gun into.

I then removed the empennage fairing and trimmed it to final shape.  I then drilled each screw hole for platenuts in the areas I could reach.  I will need to remove the VS and HS in order to rivet the platenuts.
 

8.0
2/14/09 I installed the platenuts to the front of the lower canopy by first epoxying a piece of .040 AL to the back where the platenut would be riveted.  I then countersunk and riveted the platenuts.

I then focused on attaching the gasket seal on the baffles.  This is an iterative process that involves cutting 3.0" strips of the seal material and drilling it to the baffles.  Starting at the rear and moving forward along the sides you have to drill and cleco the material on each baffle section in case you ever need to remove the baffles.

I also drilled and installed the air inlet seals.

 

8.0
2/15/09 Today I drilled the attachment strips for attaching the rudder pedals to the rudder cables.  I cannot find the clevis bolts needed to assemble so I will wait until my order arrives next week.

I spent the rest of the day working on my wing tips.  I mounted each wing tip on the wings and measured the W-916 wing tip ribs.  Due to interference with the hinges, I had to trim the ribs to fit.  I then removed the left wing tip and drilled the rib to the tip.  I also fit and started drilling the W-931 wing tip rib.
 

8.0
2/20/09 Fellow EAA member, Karl Lambert, came by and helped me decipher the instructions for installing the exhaust support brackets.

I installed the rudder cables to the rudder bars since I have the correct clevis bolts now.  I also went ahead and drilled the brake master cylinders to the pedals.

With Karl's help I crawled into the tail and covered the loose wiring running aft with corrugated tubing for chaff protection.

 

6.0
2/21/09 I got and early start and installed the fuel overflow tube as well as the oil overflow tube.

I had a site visit by Vern Darley today.  Vern will be helping me out in several ways.  I will be taking my transition flight training with him on March 7th.  He will also be serving as my DAR and this was the first time he has seen my project.  (Fortunately, he found no fatal flaws).  Lastly, Vern will be conducting the first flight for N16BL.

After Vern left I fabricated the lower cowl support bracket.

 

6.0
2/22/09 Today I focused on the wing tips.
 
 
3/6/09 I fabricated the fuel return line from the firewall to the right tank.

I also fabricated and installed the main fuel line running from the boost pump to the firewall.
 

6.0

 

     
 

Total Hours this Page

 
 

Total Hours Firewall Forward

 

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