Chapter 22 Electrical
This is the chapter that marks the
beginning of the end in the long building process that has taken me now over 6
years. I can’t believe it has been
this long. Many have commented
saying they could not do a project like this that required a long term
commitment. I think you have to
enjoy what you are doing. I do
enjoy working on the project after a long day at work. It gives you time to think about things
and gives me a real sense of accomplishment. There are two things I just can’t
comprehend about building these planes though, one is, how do some builders
complete these things in as little as 18 months?! Second, how did Nat Puffer
build 4 of these things?…..and I don’t think he started the first one until he was
in his 50’s!
There is a great quote making the
rounds in the aircraft building arena on how these planes get
completed…..
It's never skill or
craftsmanship that completes airplanes, it's the will to do so,
Patrick Kenny, EAA 275132
I guess that pretty
much sums it up!
The battery is the large black
unit lower left. The master
solenoid is the small shiney piece to the left of the
battery. The voltage regulator is above the battery. The manifold pressure unit
is upper right, and the LSE electronic ECU is lower right. Between the ECU and
the battery is the main grounding block for everything back there. I also have another grounding block on
the back of the panel that is connected through an 8AWG wire. Down below in the
“hell hole” is the high boost electric fuel pump for the fuel injection. Keep in mind this still isn’t complete
at this stage. I haven’t run the
autopilot harness for the servo and the magnetometer, Nav/Strobe lights, Electronic ignition forward harness,
mag harness, well…….and you thought I was slacking off
during my last update. Here are
some shots of the back of the panel……
You can also see the runs of the
nyloseal tubing for the pitot/static system.
I opted for two static vents for redundancy. Other builders say they don’t like using
the nyloseal tubing because it is rather rigid and
hard to form. I read on another
builder’s sight that he used a heat gun to form the tubing. This worked very well and I don’t have
to worry about any kinks in the tubing.
Next, I went about wiring up the
electric nose lift. I installed
Jack Wilhelmson’s unit and it is very nice. I also opted for the auto extension
unit. This unit will automatically
lower the nose gear once you drop below 90 knots. Like I said, a great unit, but here is
what you are looking at to wire it.
Well, just like everything else on
this plane, just one step at a time.
I took a highlighter and marked off each wire I ran. Amazingly, when I went to test it, all
the smoke stayed inside the insulation and everything worked as
planned.
Next, I installed the Nav/Strobe lights.
I held off on purchasing these until the last minute. Technology is moving very rapidly with
LED’s. This is one nice thing about
the experimental category of flying.
Some of the things we can use are so much better and cheaper than what
the FAA requires on a production plane.
The lights I purchased use LED’s for the Nav
lights. The strobe is more standard
and still requires a strobe pack.
GS air offers a low profile unit that looks like it was made for the
Cozy. Here are two shots of
it.
If you look closely at the dark
photo, you can make out the individual LED’s, some are at a more direct angle to
the camera and appear white….The nice thing about using them is the should last
much longer than a standard bulb, operate much cooler, only draw ¼ of an Amp,
and cost half of what a certified Whelan set up costs.
The last thing I did was to run
the antenna wires from the wings up to the panel for the VOR, COM, 3-light
Marker beacon, and Transponder antennas.
Once I finally got everything
wired, checked, and in place, I had to spend many hours getting it all neaten
up. I was pleased with the outcome
for a first time wiring. Here are
the results……
Here is a shot of the panel all
installed and fired up…..
The hole at the top of the radio
stack is for the Garmin 496 portable that I am waiting
to purchase after