GEA 24 doubler

Just like the GAD 29, I had to install a doubler for the GEA 24 engine sensors.

These would have been more accessible on the front side of F-768, but I could not get them to fit without interference from either the canopy longeron gusset, the tip up canopy reinforcement angle, or whatever.. so it will match the other side.

The GEA 24 is a little bigger than the GAD 29, so obviously the doubler is too. I tried to minimize the size (weight) but it needed to span the lightening holes in the F-745-R rib.

GAD 29 doubler

Haven't done the best updating this, here was today's work

• Replaced F-745L fuselage rib
• fabricated doubler to hold GAD 29
• primed (stewart systems ecoprime) upper forward fuselage parts  F-745L fuselage rib, F-768-L outboard sub panel, WD-745-L (replaced with new) and WD-745-R canopy rails, F-631-A (-R and -L) canopy rear supports, and ELT bracket 
• came out rough textured, first time using HVLP spray gun. Finished product is OK and looks good. Primer seems to be tougher than spray paint primer attempts.
• Installed GDL 39R on co-pilot ELT bracket (hard to get bottom pop rivets in there)

Previously, installed AP Hub and GSA 28 pitch servo controller

Reinforced F-768 with J channel to support GSU 25 AHDARS...too low will interefere with slope in part - need to redo higher up

F-745-L doubler reinforcement

F-745-L with GAD 29 installed

Full subpanel test assembled on bench

GDL-39R installed behind baggage 

GDL-39R using Van's ELT bracket

GDL 39R mounted on bracket

Rebuilding Canopy

The canopy was not fitting well, and could use a little improvement. This is the nortoriously hardest part to build, so I'm starting over.

Replaced the WD- canopy side rail. You can see the holes are oblong and it was twisted too.

You can compare the old and new. I switched to water based, less hazardous primer. Unfortunately, it is not very grey, more of a white.

Also replaced the top skin of the canopy frame

This will take some work to get it all lined up in the existing holes of the forward canopy frame.

I also had to replace the rear canopy frame.

You can see that a tooling hole from production of the part is interfering with some drilled holes for rivets, so for my replacement parts I used some JB Weld to fill the holes

Hard to see here, but it's there.. not perfect but at least will provide some material to drill through.

Autopilot Hub wiring

The autopilot wiring runs to a central hub, provided by SteinAir. This simplifies the wiring runs and the CAN bus. However, I needed to determine the length of wire to run from the hub to each component.

Estimated Lengths
GSA 28 HUB to:
GDL 39R (ADB weather/traffic)

• 20 AWG black/red (power/ground) ~20 ft.
• 22 AWG shielded 2 conductor (signal) ~20 ft.

GTX 23ES (transponder): 

• 20 AWG black/red (power/ground) ~15 ft.
• 22 AWG shielded 2 conductor (signal) ~15 ft.

GSA 28 (A/P roll servo)

• 20 AWG black/red (power/ground) ~20 ft.
• 22 AWG shielded 2 conductor *2 (RS232 and CAN signal) ~40 ft. @ 20 ft. ea.

GSA 28 (A/P pitch servo)

• 20 AWG black/red (power/ground) ~1.5 ft.
• 22 AWG shielded 2 conductor *2 (RS232 and CAN signal) ~3 ft. @ 1.5 ft. ea.

Flap hardware and A/P install

Flaps

• removed steel flap assembly and swapped bolt/nut configurations so bolt head is facing outboard vs. inboard. With the bolt head inboard, the nut can interfere and catch the rudder cable
• removed vertical flap housing to replace 470-4-4 rivets with 426-4-4 flush rivets. This allows more clearance between canopy tip latch weldment tube and the flap housing F-705

Wing

• Started install of GSA 28 autopilot servo motor bracket