Beringer Brakes, Jury Struts and Landing Lights

Yesterday, I mocked up a bracket for the Beringer Proportioning Valve. I relocated it between the seats in an effort to simplify the installation. It looks like it will work out ok in this position. I've ordered some different banjo bolt fittings and will know when they come in. Then I'll focus on the parking brake unit. I set a seat frame and cushion in to check fit and it looks ok.

This morning, I wanted to get the jury struts mounted to the wing struts. Besides getting them attached, I didn't want to screw up the powder coat. Got it done without a scratch.

Up next, I mounted the landing lights. Again, the object was to get them mounted without scratching up anything. Done and connected.

Wing Adjustments, Wing Tanks, WIring, ECU

I've been at a stand still for a couple of days because I can't lift the tail by myself, at least not high enough to get it level. Today, with Chris's help, I was able to lift the tail into a level flight attitude.

I had previously set the wing tanks and compression tubes in but not tightened anything down because I needed to make some final adjustments on the wing first. Chris and I got side tracked and started brainstorming the wing wire routing as I was supposed to have this already done. However, I had several questions and wanted to wait for his input. This was a bit of a puzzle and proved to be interesting too. After working on it for some time we finally came up with a good workable solution and Chris got to work on the left wing wiring and laced it up. The exit was good, we double checked that we had enough of a service loop by swinging the wings into the folded position without stress. Additionally, we were clear of all the fuel line entries and exits.

That's when it hit me that the tanks were not finalized and bolted in. The wires were in the way of bolting the tanks in so, I had Chris stop and told him I would finish mounting the tanks later today and we could resume tomorrow. So, I had to undo some of what Chris had done to pull the wire bundle out of the way so I could work on the tanks.

However, there was another task I needed to complete first. I needed to adjust the trailing strut rod bearing on the right wing. The wing adjustments needed to be finalized before mounting the wing tanks. That is why I hadn't bolted them in. When I put the struts on the wing before mounting I wasn't able to set the rod end correctly. So, with the wings finally in level attitude I was able to support the left wing while lifting the right wing to take the pressure off the bolt so I could remove it and adjust the rod end bearing. Once adjusted, I was able to relieve the pressure enough to reinsert the bolt with the proper spacer washers and tighten it for good. I had to preform the same procedure on the left wing. Now both wing struts are adjusted and have been final torqued.

Right Wing Rod End Bearing with washer spacers

Left Wing Rod End Bearing with washer spacers

Not really exciting but crucial. 

Now I could get back to installing the wing tanks. It is a trial and error proposition. The object is to get the compression tubes, that the tanks bolt to, to be level with the flanges on the tanks. NOT level with the ground. Each compression tube bolts in two places, fore and aft. There are washers the are placed under or over each end of the tube to accomplish this leveling. One places the washers fore and aft, in the quantity that looks sufficient, mount the tanks to see if the flanges sit level on the tubes, if not, pull the tank out and try again. This goes on until the flanges and tubes have no gaps, or as close as possible. The reason for this circus is so no warp or twist is induced on the tanks when bolted in, preventing stress and leaks. It is a time consuming task preformed while balancing atop a ladder reaching over the wing, lifting the tanks in and out multiple times, three time each side to be exact. NOT a good time. I also didn't snap any action pics of this. However, it is done, the tanks are mounted.

I was able to get the left wing tank installed and rerouted the wiring back into the position that Chris had it. That's when it hit me, if I have any problem with the tanks I won't be able to remove them without cutting wiring. Not good. I called it quits for the evening after getting the right wing tank installed. I would get the left one tomorrow.

This morning I got the left tank leveled and installed while waiting for Chris to show up. When he arrived, I told him about the problem of the wire routing and tank removal. I originally had expressed a wish to be able to remove the wings without having to cut wiring. Way back when, we gave some thought to it and I actually purchased some cannon plugs in an effort to develop a way of splitting the wires at the wing. I eventually abandon the idea and moved on to other construction tasks.

So, here we were again and I had spent last evening thinking on it again. I came up with the idea of a D-Sub connector, like a printer plug, and wondered if it might be a workable solution? We talked about it and agreed that not being able to remove the "removable" wing tanks without cutting wires was a problem. After some discussion and fiddling, we set about making a bracket for a D-Sub connector and mounting it. It seems to be a workable solution providing a way to not only remove the wing tanks but the wing itself without cutting wires. That is huge. I gave Chris the go ahead and he cut the wire bundle and started preparing it for the D-Sub connector.

First attempt for the right wing with 1/2 of the connector in place, had to order the mounting hardware.

Without the connector

The larger one is the second iteration for the left wing.

A couple of shots of the wires in the connector on the right wing. The above bracket is not installed yet nor are the wires weather proofed. The above bracket goes to the right of the plug in the pic, you can see two small screw holes between the large lightening holes that the bracket uses. To the right and up at the top of the rib, you can see the two side by side holes in the tank, one for a vent and the other for the fuel gauge tubing. Note: the butt rib is not in place in these pics. You can see the stand offs for the butt rib, the gray vertical ovals with two screw holes on each end of the rib

The last project for today was to fab a tray for the engine ECU and temporarily install it. It's pushed back to allow for the large cable that attaches to it. This will allow some flexibility in routing the cable though the firewall. It also can be swapped to the other side of the fuselage or, it can be mounted upside down if necessary.

Visit with Terry, Small Items

Today I ran down to visit with Terry and check out the progress on his Kitfox. Chris has finished up with the wiring of his panel and has got everything working. Now he's in the programming mode. A few more things to do there and Terry will be able to put the windshield/boot cowl back on and finish up the build. The first engine start is within a week or so, then final inspection. Good Job Terry!

The big coil of wire in the foreground is the programming cable. It will be removed once programming is complete.

It's all working!

Now, Chris can get back to work on mine...

Speaking of working on mine, I did get a couple of things done. 

For the past several days I've been working on the Beringer brakes. I started by laying out all the inventoried parts. The master cylinders are already mounted to the pedals in the aircraft.

First thing was to make up a couple of brake lines and temporarily install them checking for fit. I have some issues where the wires come up to the panel but will get that sorted.

Next up, I needed to determine where the optional ALIR (proportional valve), kind of like an anti-lock brake system, was to be mounted. It's not exactly easy to locate as it goes in between the pedals and the parking brake unit (which I also need to find an appropriate place to mount it). The ALIR valve is pretty much a set it and forget it valve. So, constant access isn't required, which helps in finding a place for it. In my case, just in front of the passenger seat under the elevator control structure.

 Two lines in from the pedals, two lines out to the parking brake (not yet installed).

A shot of the co-pilot pedals with the lines going to the ALIR cris-crossing under the pedal brackets going back to the ALIR.

Another shot of the co-pilot master cylinders with the lines temporarily attached. This is looking "through" the firewall at the pedals.

 

Taking a break from thinking about the brakes, I needed to finish up running the electrical wire from the rudder strobe light into the fuselage. I decided to try my hand at making a fairing for that line. I needed something small, just to cover the hole and provide some protection. I painted the fairing matte black to match everything else and left it to dry over night.

Once I was finished with that I burned a few holes in the fabric, just big enough to allow the plug to pass through. I passed the plug inside and connected it to it's mate to complete the connection.

This morning, I applied some Super Glue and mounted it to finish that task. The wire passes cleanly through and is uninhibited in its movement through the full throw of the rudder.

WIngs, Firewall

I secured the wing bolts at the fuselage today with washers, castle nuts and cotter pins. Afterward, I applied torque seal to all.

Left Upper

Left Lower

Right Upper

Right Lower

Then I set about installing the wing tips and navigation lights. I installed the mount for the light using the previously installed lock plates, so it was just a matter of screwing the mount on. Then, I mounted the light and secured it with the provided set screw. I connected the wire plugs that were previously installed and mounted the whole piece again, using the previously installed lock plates.

Right Wing Tip

Left Wing Tip

The last project for the day was to remove the firewall so I could access the brakes. I first had to suspend the avionics tray toward the front as it attaches to the firewall, using several zip ties. The next project is to install the brake lines to the pedals. This also will give Chris much easier access to finish up the wiring in the panel.