[79FT]: Building Things
...misery turned happy times!
|On:||Sep 10, 2019|
|In:||[Chickenhouse Charger] Electrical Rebuild|
|Tags:||6781G, MA5 Charger, electrical, panel, drilling|
...this is important. Stick a pin in it.
Remo had these nice placards all over the airplane. Professionally done. Very well looking. He probably ordered them somewhere, or used a technique I am not aware of.
These placards are mostly glued on, and do not come off.
How do I know?
Well, I needed to remove one, in the side conduit. Here it is,..
..to the right of the future fuse block. It gets in the way - there will be another fuse block there to the right of the one on the picture. And I can't rip it off! I can't remove the conduit to immerse it into whatever solvent will cut the glue without some major surgery, so I guess the new fuse block will go on top of it.
Why am I telling you this?
You have probably figured by now that I have a taste for misery, and for ranting about how miserable that or this was :). If you read a few notes in this Dear Diary, you will notice a trend - that I tend to come up with ways of making myself aggravated, very consistently and reliably.
Well, this time it was the "anti-rotation" holes for switches in the panel; and the plan was to drill them from the back side of the panel not quite all the way thru (yay, no access and contortionism again!)
Every switch, circuit breaker, and certainly, a dimmer, comes with a "keyed" washer to prevent it's rotation. That means you're drilling two holes - one for the appliance (switch, or whatever), and the other for the little tab that's on the washer.
Picture explains this better. Here is a little hole template I quickly drew in Solidworks, properly dimensioned, with washers from (left to right) the circuit breaker, switch, and the dimmer.
See, Remo didn't have those "secondary" holes on the panel - so I had to drill them (especially for the dimmer).
But wait, you ask. If you drill holes, that will be ugly - a hole next to every switch?
Yup. Aha. Agreed! Though the nuts are supposed to cover them, they, I'm pretty sure, from my testing at least, wouldn't have...
No problem! Remo made the panel from 1/8" thick aluminum, and I needed maybe half that much for the tabs to go in. So the plan was to very carefully drill them just deep enough to house the tabs.
Made me a nice little set of templates...
Templates in the making
...out of a small piece of aluminum, drilled holes using my paper template, and cut them up...
Templates, cut up
...and cleaned up the holes and edges.
The plan was, to put a template like a "washer" around a switch/CB/..., and center punch the secondary, small, hole, thru it. Then, I'll have punch marks to drill, and will have to either get to them from the side of the plane, or, more likely, from the back of the panel while sitting in the seat and not seeing where they are while drilling, using a mirror to position the drill first.
Like I said, I have a taste for misery.
So there we went, punching the back side.
Center-punching on the back side of the panel
Cling! Ding! Ding dang dong.. it sounded like a chunk of metal just fell off the plane and dropped on the cockpit floor.
!??!?@??!??! What the h... did I break?!
I crawled out from behind the panel and looked into the cockpit.
On the floor, looking at me, and almost smiling, was...
...this. Remo's placard that went around the switches. Like so:
Placards - in place
Wait, wait wait wait. It came off. But it will be held back by the switches' nuts when the switches are in. And.. cover the holes! That means, I don't need to drill the holes from the back side and worry about punching thru (or not going deep enough) - I can comfortably sit in the cockpit and drill them from the front! All the way thru! The placard will cover them! In my search for misery, did I luck out?! :)
In retrospect, this (and the opposite side's) placard were probably not glued. No need - switches' nuts hold them just fine.
They were stuck because Remo probably installed them on top of the paint that didn't fully cure - and it just stuck to the backside of placards over the years, under the pressure from switches' nuts.
I stuck my nail under the opposite side placard, and it came off with a little force.
Well, it was smooth sailing from there...
Marking from the front
... relatively speaking, of course. I still had to hold up the vacuum with my knee, and maneuver the sharp drill, making sure to be extra careful not to poke it into anything important (like, fabric on the sides).
The ones on the corners were annoying; but I already had the drill bit installed into one of my hex drill adapters - so a 90 degree adapter was not an issue. Didn't even need an angle drill.
Angle adapter for the side hole
That sucker has 1/4" diameter threads; and all the holes I have in the panel are 1/2... Without some serious bushings, or other mods, or a new hole.. ugh.
Possible pot locations
I was hoping to stick it into the old "Master Circuit Breaker" hole (marked (2) above), but it was waaaay too big.
Looking around, looking around.... aha! Here's a number 8 or 10 screw plugging a hole! I can enlarge it and we'll be in business! (marked (1)).
Yep. Good luck, buddy. That was an even bigger hole that was plugged with a #8 screw in a countersunk finishing washer... hmmm... maybe that will work out for the pot too?
You know, drilling a #10 countersunk washer to have a 1/4" hole in it is... hard? Annoying? You can't really grip it in any manner without damaging it, you can't hold it in your fingers... I think I lucked out on my third try, with combination of a Unibit and light clamping of that washer in a vice.
With that re-drilled countersunk washer, the pot mounts just fine in hole #2. And #1 got plugged back :).
Well, after all that excitement compass mount was almost anti climactic. I toyed with the idea of putting it into the panel (and relocating G-meter into a new hole I'd cut around where the ignition switch was - see, after having failed relocating Hobbs there, the idea of still making a bigger hole in the panel keeps nagging me :).
No good. When that much down, too much steel around it confuses the compass to the tune of about 30 degrees... No need to add extra problems in already a magnetically problematic plane.
So, top it was to be. The windshield will get in the way, but I really, really didn't want to take it off (~20 #6 screws and nuts in a tight spot is no fun).
Eyeballed the bracket alignment with the fuselage centerline and put it in the right spot...
Damn! Sharpie's too tall to get in there to mark the holes vertically. "Angle Sharpie Adapter"... hmm..
Angle Sharpie Adapter
A bit of disassembly and forceps do the trick ;).
Holes punched and drilled, I added a bit of rubber foam under a portion of the mount to "eat up" uneven surface created by combing...
Vertical card compass!
Side note to attentive folks: yes, I know I need brass hardware - those CSK washers and SS CSK screws are temp fasteners I used to test positioning. It will be brass, I promise :).
Oh, by the way, the best accompaniment (score? ;) ) for working on a biplane is...
... The Chairman, of course!
Airspeed, altitude, or brains; you always need at least two.
...messing around trying things
|On:||Sep 08, 2019|
|In:||[Chickenhouse Charger] Electrical Rebuild|
|Tags:||6781G, MA5 Charger, electrical, fwf, panel|
I was on the fence about making this entry as multiple separate ones versus just one giant one... After all, it covers quite a few, mostly unrelated, things that I did in the last few days, and it would've made sense to keep them separate.
However; finally decided to make just one big article with all of them. None of them are finished; but somewhat a decent chunk of work is - I think I have mostly figured out where everything will go and how it will all come together.
I guess, what I'm trying to say is, if you clicked on the "Panel Layout" entry in the Log, and are trying to figure out why are you seeing notes on Firewall Forward, just keep scrolling :).
I have updated the electrical diagram, version 2 is here.
I started trying things around firewall forward while figuring out routing and lengths for carb control cables, and continued afterwards.
It became obvious fairly quickly that I won't be able to use the nice B&C Starter Contactor because of it's mounting holes not being the same as a very common SS581 Starter Solenoid that was set up by Remo. Also, the way terminals were set up on the B&C Starter Contactor would have made them closer to the carb control cables. And, I didn't want to drill more holes in the firewall.
So I decided to go with SS581-style and ordered one from Vans. While waiting for it, I used the old one just to mock things up.
And because it doesn't have the spike catcher diode, I had to get me a couple IN5400s, and soldered an extension lead to one of them.
The other leg will get a crimp ring terminal. I had to do that 'cause the diode leads themselves weren't long enough.
Those are the thickest wires, and routing them is more complicated than the other ones. In addition, the battery + -> master contactor wire is the only wire that can't be turned off, and therefore needs to be very well thought out and as short as possible.
Here's something else, too. The Charger was set up to ground the battery to the motor. So far, so good - starter is by far the largest consumer in the electrical system. However, nothing was done to ground the motor to the rest of the airplane!
So the rest of the system was probably grounded via whatever metal to metal connections there were on the motor. Control cables and braided fuel and oil hoses? ;) Airbox bowden "carb heat" cable... I can't think of much more else.
Initially, I was planning to run a ground strap braid from the battery negative to one of the bolts holding the battery box to the firewall, but with fuel system components and control cables around, just couldn't figure out a good way to run it and support it. I had to end up settling for running it to the engine mount instead.
So the bottom line is, the negative 4GA cable is gonna go to the motor, and parallel to it a braid will go to the motor mount. I also figured out a clamp arrangement with some standoffs that will keep the wires neat and organized.
Beefy Wires - side view
Beefy Wires - top view
Negative leads and grounding
Oh hey, and I practiced my lacing on those ignition wires. One of my plans is to excise all the zipties I can get to, and replace them with lacing cord ;).
ANLs and the Ammeter Shunt will go to where no man had go... 'cuse me, to where the old Voltage Regulator was. Like this:
ANLs and Shunt placement
I will need to make a backplate for them to re-use the old voltage regulator mounts, and not have to drill new holes in the firewall. I used my Solidworks templating trick, and made me a nice template...
... and a mockup (with material, as usual, courtesy of USPS).
The shunt is offset "down" due to the top hole in the backplate (which will have one of three holddown screws to hook up to the old voltage regulator mounts), and I couldn't use buss bar stock to connect the stud terminals on the shunt and ANL bases - if I were to do that, it would not let the ANL covers to come on. So, before doing anything drastic, I decided to check to see how it would look with the wire jumpers
One side done
Second ring on the jumper
On the firewall
I liked the way jumpers came out a lot, and will probably keep them that way. They do add just a bit of weight, but not enough for me to worry about.
The Voltage Regulator and the Main Terminal/Fuse Block were to go to the Side Conduit running alongside the fuselage.
Rough component locations
I had to relocate the bowdens lower to free up some space. The Oil Cooler box on this plane is all sorts of weird, including a flapper valve controlled by one of those bowdens that closes up the airflow to it (which is not enough to begin with; being a 1.5" SCAT takeoff off of back baffle.. but don't get me started on that). That cable turned out to be too short when relocated - but I lucked out - Glenn had a bowden going to the Rotec TBI that I removed for "prime" function, and that bowden was plenty long. I'll trim it to final length when I'm done in that side conduit.
The brake tube was running inside the conduit, and I will have to relocate it to run below the conduit and be supported by adel clamps. For now, I unhooked it and used it to somewhat mock up the new run. Tube and fittings ordered, and tubing bender already here!
I was gonna use a 20-position fuse block from B&C. Well, that didn't go too well.
Tight! I basically lose the whole top row of fuses with it. Not enough room....
After poking around the Internets for a bit, came to these nice fuse blocks made by Blue Sea Systems. Longest ones they have are 8 fuses, so I will need two (if I recall correctly, I have 13 fuses in the diagram currently, and I want some spare positions for later if I need them).
Blue Sea Systems fuse block
Much better! Plus, they use ring terminals rather than tabs - and while tabs are light and simple, I don't like them. Removing them is hard, and, when removed, the terminal loses a lot of it's grip. It's almost like an "assemble once" type deal.
With how the wire harness is gonna go in that conduit, and with bowdens being where they are, the best orientation for the Voltage Regulator would've been "upside down", with terminal strip up.
Upside Down orientation
Damn you, the yellow sticker on the regulator! DAMN you! (hint: read it :) ).
Mounting it sideways, I'd have a line of rivet heads under it - which I didn't want to deal with.
And mounting it down... Down was annoying because of the clamp for bowdens and bowdens close there. That would also complicate wiring.
Upside down would've been perfect... except for that yellow sticker :). So, I decided to Hail Mary and asked nice folks at B&C about what they thought.
See, the problem is I know why they wanted the terminal strip to be pointed down. It's so that water won't get into the box in case of condensation accumulating on it. But I thought, maybe I can seal it somehow?
The answer from TJ at B&C was a resounding no. Right side up, sideways - but not upside down.
So I mocked up the right side up mounting...
Right side up mockup
Yuck. Yeah; it'd work; but it's ugly as hell.
The only other option would be sideways, but on "standoffs" of sorts to clear the rivet heads. I mentioned that to TJ, and he said that that could work, but I should check if I can access the voltage adjustment screw on the top of the box.
Damn it! I forgot about it. On the top of the box there's a plug over a hole that opens up access to a tiny screw to adjust buss voltage - basically, to fine tune how much volts the battery sees. Not something you do often, but you want to be able to do it.
But then, TJ mentioned that he saw the holes in the firewall and that might be the saving grace.
I tried it out again in vertical, now with mocked up standoffs
With just enough aggravation due to bad access (mandatory in aviation pretty much), you can undo the bolt covering the hole in the firewall (this hole was left over from the brake line relocation), pop the plug on the voltage regulator, and just have enough access to the adjustment screw.
Adjustment screw - firewall side
Adjustment screw - conduit side
We got ourselves a winner, I think!
Hobbs was on the front panel, probably because of space issues on the rear panel.
"Aux Generator", eh? :) (read what the gauge says).
Well, I had this unsightly hole left over after removing the ignition key switch...
... and I thought, maybe I could put the Hobbs back there?
My initial tests with one of the 2 1/4 gauges I have removed seemed to have been okay: there was just enough room in there to get another 2 1/4 gauge in.
So, I got me a very nice panel punch that could make a nice, round, clean hole in place.
Instrument Hole Punch
Well, next was to remove the Hobbs from the front panel. That was an hour of contortionism. The Hobbs is held by an aluminum backplate and four nylock nuts, so I had to have a wrench over them the whole time. Oh, the screws are way too long BTW, so taking all them out took about five times more turns than it should've, while I was wondering if my wrists will take this much flexing, twisting, and bending any longer.
This is a pic from the fuel quantity gauge held in the same manner, but here he's using brass flat type nuts that you can hold with your fingers. On the Hobbs, it was nylocks.
Anyway, I got it out. And then, started setting up for punching that hole. Removed VSI to give me a bit more room to work with.
I tried to reconstruct exactly what happened next in my memory to write it down here, and could not. I was basically fiddling, checking clearances, making sure I'll be able to hook up the punch and center the hole, have enough room for the mounting ring in the back and clear everything I had to clear, when I discovered that...
The Hobbs was not a standard 2 1/4 inch gauge - it was a touch bigger. So the hole that I would've made would've been too small for it. And that if I punched the hole, I would've been just left with a bigger hole and nothing to put in there.
Damn, damn, damn! Damn you, assumptions that every "small" gauge on an airplane is 2 1/4!
And I had the expensive punch that I had no use for :(.
Oh well. Thanks God I actually did not do it - only to have a larger hole to plug up. I guess, that Hobbs is (thru more contortionism) going back to the front panel.
As they say, Le Sigh.
Finally, something fun! I put in the switches to play with layout. Here's the first, and (after playing with moving things around and pretend turning them on and off), the best, layout.
On the right side, I might clump the switches together, or leave them as on the picture, to "match" the placards (those are left over placards from fuses that were there in the old electrical system). The little brass knob on the right is gonna be panel lighting control pot.
I am going to replace Pilot's whiskey compass with a vertical card one - yes, I am directionally retarded :) It's not that expensive a mod in the grand scheme of things; and is the only directional instrument available to pilot on this plane (no DG ;) ).
It's a bit taller than the whiskey compass, so I'm playing with different mount locations. I think this is what it will be; with shock isolating rubber pad under the mount where the gap is at the moment.
One of the evenings, I wanted to make sure the Fuel Gauge was still okay (I had a suspicion that it wasn't - turned out to be false).
But first, I wanted to clean up the wiring on the tank sender.
The terminals on it are "automotive" style, without insulation support.
There. No zipties, good terminals, and marked :)
"Caution wake turbulence you're following a heavy 12 o'clock, three ... no, let's make it five miles."
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This website only shows how I did things in my various projects. These pages are for information and personal entertainment only and not to be construed as the only way, or even the perceived correct way of doing things. You are responsible for your own safety and techniques.