Archive for October, 2009

GPS antennas

Saturday, October 31st, 2009

My airplane needs a bunch of external antennas on top of the fuselage… one WAAS GPS antenna for each 430W, and a combined GPS/XM antenna for the G3X system. I cut up some 0.063" alclad and made a doubler for each antenna:

I chose to put the two WAAS GPS antennas on either side of the canopy track, about halfway between the F-706 and F-707 bulkheads. As long as they're not placed too far forward, the canopy will pass over the top of them as it lifts up and slides aft. I couldn't put them all the way at the aft end of the canopy track, since the upper fuselage stringers taper together and make it too narrow to for the antenna doublers to fit. I used a yardstick as a spacer to make sure I drilled the doublers parallel to the fuselage centerline, and to ensure adequate space for the canopy slider block to pass by.

Lots of big and small holes drilled in the top of the fuselage… no turning back now! The doublers will be riveted to the inside of the skin, of course, but it's way easier to drill them from the outside. I also had to shape them a bit with hand seamers, since a perfectly flat doubler won't quite lay down on the curved fuselage skin.

The third antenna doubler is located just aft of the F-707 bulkhead. There's plenty of room for the canopy slider block to fit between the antenna and the end of the track, so there should be no problem removing/reinstalling the canopy.

I alodined the doublers and fuselage skin for good electrical bonding, and riveted on floating nutplates.

John came over to help buck the rivets, while I crawled back into the tailcone to drive them from the inside.

The actual riveting went pretty quickly:

A shot of the finished rear antenna doubler:

Now the fuselage has sprouted a crop of antennas:

Victory! Thanks to John for the help.

Trim wiring

Sunday, October 18th, 2009

Not a lot of time to work on the airplane this weekend, but I did manage to finish wiring the aileron/elevator trim controller:

Need to order some more shielded wire in order to continue… not to mention find some time to work on the airplane for a change!

AOA wiring & indicator

Sunday, October 11th, 2009

The AFS angle of attack system comes with a wiring harness of sorts… actually it's just a a bundle of wire several feet long, with a d-sub connector on one end. Rather than try to splice their provided wiring into my electrical system, I just de-pinned all the wires except the ribbon cable that attaches the brain box to the display.

Then I ran all the various wires to the AOA brain box… power, ground, button inputs, flap detect switch, etc. Which looks a lot like a bunch of wires and a box:

I spent a couple days playing with scraps of sheet metal until I'd built a little cosmetic housing for the AOA system's glareshield display. The battery in my camera was dead, so sadly I don't have any photos of the process, but basically I just hammer-formed it out of thin alclad over wood blocks. The shape ended up being somewhat strange, since it has to sit level on the sloping glareshield.

Riveted together and painted… Sadly, I forgot to take a picture of the finished product mounted on the glareshield, but I'll put one up when I install it for good.

I did manage to get a photo of the grommet I put in the forward fuselage skin for the AOA display wires, which is much less interesting:

I plugged the display into the ribbon cable to give the AOA setup a basic functionality test. All the lights came on, so I guess it's working.

The ribbon cable connector is kind of a one-shot deal, so rather than risk breaking it trying to get it to release its grip on the ribbon cable, I just cut off the last foot or so and put it back in the box until I need to install it permanently.

The remaining length of ribbon cable will remain spooled up in the cockpit until I finally install the AOA display for good, at which point I'll cut it to length and splice the wires back together.