Wiring

July 5th, 2009

Lots of wiring but not very many pictures today. I ran the power and potentiometer wires to the dimmer unit, and connected the Garmin avionics (all seven boxes!) to one of the analog outputs. I do not like these little screw connectors… give me a D-sub and a bag of gold crimp pins any day.

I also hooked up the CO detector, and verified it's alive by listening to the annunciator light output pulsing my continuity detector when I pulled the test pin to ground. If you're not an engineer, don't worry if that sentence made no sense, just nod and keep reading.

Here's another "look at all these crazy wires!" picture:

ADI wiring

July 4th, 2009

I can't afford a real two-inch standby attitude gyro (they cost a mint… and I'm talking this kind of mint, not this one) so I have a TruTrak ADI instead. It's not a real attitude indicator, but it should be good enough for a backup instrument. And since it's a safety-of-flight item, I wanted to make sure it was fed by dual power paths, as are the other most important avionics in my panel. Unfortunately TruTrak didn't provide dual diode-isolated power inputs like Garmin did, so I had to use a pair of 1N4001s to create my own:

Heatshrink tubing protects against shorts – after I took this photo I added another piece, then crammed the whole assembly into the D-sub backshell. One side is fed by Bus 2, which powers my important avionics, and the other side is fed by the standby battery. This arrangement will also keep the gyro alive while cranking the engine, which might be a good thing considering some of the funny behavior Matthew reported when he had his ADI powered on while starting.

Here it is mounted in the panel… I verified that it powers on, figures out which way is up, and receives GPS data.

Port-side view of the ADI wiring harness. The D-sub connector comes pretty close to the panel, but there's enough room to avoid kinking any wires. However, it would not have fit if I'd mounted it in the center standby instrument hole as I'd planned, which is why I moved it to the top.

"But I thought the ADI wouldn't fit in the top hole!" you say, or at least that's what you might say if I allowed comments on this blog, which thanks to the efforts of spammers I don't, thank you very much spammers. "You even posted a photo of this exact thing!" you might also exclaim if I let you. Well, yes, but that was before I figured out that a UMA light bezel inserted ahead of the instrument spaces it back far enough to clear the panel frame:

So thanks to the light bezel the ADI now lives at the top of the stack of standby instruments.

This is actually great news, because I was already planning to use UMA light bezels for my standby altimeter and airspeed indicator, and I was bothered by the fact that the ADI's internal lighting didn't match them in color or intensity. So, I broke out my Fluke and did some probing around… It turns out that I was able to defeat the ADI's internal lighting by connecting the 5V output pin on the dimmer unit to the ADI pin that's designed to be connected to a 24V lighting bus. What happens is that when I turn on the nav light switch, thus energizing the dimmer, the ADI sees five volts on its 24V lighting input (equivalent to 2.5V with a 12V lighting bus) and reduces the brightness of its orange LED display… but 5V isn't high enough to turn on its internal lighting, so I'm free to use my light bezel to light the instrument face instead. The dimmer potentiometers don't care about the extra milliamp or two that the ADI sinks on its lighting input pin. Excellent.

If you're still awake after reading the above paragraph… yes, I can be a huge geek sometimes.

Wiring

June 28th, 2009

Spent the whole day running wires. Not much worth photographing other than the occasional "look at all these crazy wires!" picture.

The main transverse wire bundle is getting pretty fat (average human thumb shown for reference).

Carbon monoxide detector

June 27th, 2009

Continuing to install little boxes behind the panel… this is a CO Guardian carbon monoxide detector, which I think is a worthwhile addition considering the cabin heat comes directly off one of the exhaust pipes. I made a little template out of some scrap aluminum to help me drill the mounting holes.

I attached the CO detector to the subpanel, to the right of the radio stack, with the screws on the forward (firewall) side. I was going to turn it around the other way, but there are too many things on the opposite side of the subapanel already and this is the only place it would fit.

Another view:

Here's a view from the other side, showing the mounting screws and the air inlet hole. It should be easy enough to get a screwdriver back under there to take it out every now and then – the sensor has a limited lifetime and has to be sent in for periodic replacement every few years (5? 7? I can't remember).

After I finished taking these pictures, I removed the CO detector and put it back in its plastic baggie to prevent drill chips from falling down into its little fan. Still a lot of construction going on in the vicinity.

AOA box

June 27th, 2009

The AFS angle of attack system includes a sensor/processor box that takes up quite a bit of real estate. It also has a big connector and a set of pneumatic ports that are on opposite ends of the box, which doesn't help. At least it doesn't weigh much.

I had to take the cover off the box to see what was inside. Kind of an old-looking board design. Oh well, if it isn't broke, et cetera. Dig how they used really long machine screws as cheap heatsinks for their power transistors.

To mount the box, I bent up this bracket out of 0.025" alclad:

Short screws and Loctite attach the box to the bracket:

The two leftmost mounting screws on the bus 1 fuseblock go into the nutplates on the AOA box mounting bracket (visible above).

Here it is attached to the forward side of the subpanel. This is pretty much the only place I could find to mount it. If it ever has to come out for service, it will be easy to remove those two screws and drop the whole thing out from underneath the panel.