Europa #435 G-RODO Build Journal - 2012 08

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8 Check current draw of electrical items from specs where available or by measurement (12V-24V converter & T+S, VDO fuel gauge, fuel pump, hourmeter). Notice that the UMA tachometer has an hourmeter output that only comes alive above 1800 RPM, so the vacuum switch I got is redundant! Update load analysis file. Make fuel schema to help get clear where all components fit in and which lines go where.
9 Check current draw of Garmin GPSmap 296 by measurement and add to load analysis.
10 Check Rotax alternator max output spec; it's 22A, safely above the max drain of 18.2A predicted by the load analysis file for all flight phases. Check number of fuses needed on main bus-bar - it's now 22 and I only have 2-off 10-way fuse boards.
14 Order 6-way B&C fuseblock form Airworld, plus some inline fuseholders and screened cable.
15 Mark with fine pen and cut from PLY2 sheet 2 off 565mm x 75mm and 1 off 565mm x 120mm. Get dowel from box 2; already correct length. Mount in lathe chuck and set running as true as possible by eye. Drill through with 6.5mm wood bit for AN4-31A bolt which is a nice sliding fit. Get bump stop hose from box 2; tidy up hacksaw marks at one end with scalpel. It will need trimming to length. 1431.1
17 Collect Airworld order from sorting office. Inline fuseholders do not have explicit means of securing although otherwise very nice.
18 Check fuselage fore-and-aft angle - 2.9 degrees nose-up. Fuselage floor under mass-balance weight position is 5.1 degrees nose-down. Thus trim angle for bottom of pitch control stop side support is 8 degrees. Mark angle on ply pieces and saw off. Check angle of ply in position and adjust angle slightly with TC file. Trim hose to length, slide onto dowel and tidy ends with a scalpel. Make a 10mm spacer from a scrap of wood. Offer up 1 side piece, dowel and spacer against pitch pushrod with dowel centralised in both width of ply and weight position. Mark position of dowel on ply with a 6.5mm wood bit pushed through. Align both side pieces and drill through with 6.5mm wood-boring bit. Trial assemble and clearance from pushrod seems OK. Tidy up wire stock file and cross-check with parts database. Sort out through electrical items, separating out those now redundant & noting terminal sizes for wiring file on those to be used. Have a look at the Bob Nuckolls Aeroelectric website and find he offers inline fuseholders with mounting tabs. Order 6 plus some coax cable & coax stripper. Mark out the slots in the containment bulkhead. Make the inner end radii with a 50mm Forstner bit and a 64mm holesaw. Saw out the slots. 1432.9
20 Add more wires to wire labelling database. Improve it to allow easy listing of all types of terminations used. After some online research, (RS website rather fruitless) order more ring crimp terminals from Farnell and Parts For Aircraft. Difficult to get small-size ring terminals in yellow (10-12AWG) size crimps so order some male blade terminals that can be drilled to suit the 3.5mm & 4mm screw terminals on the master switches and the 30A breakers.
21 Phone Conair about Schicke regulator and they say they don't stock it as there is no demand! Suggest I order direct from Germany. Send e-mail to Schicke. Work on main circuit diagram, moving some things around and adding wire label numbers. Have a look at the crowbar parts and consider it would be good to put both breakers and the relay in a box with the crowbar module. Also it seems advisable to put a screening box around the mag switches. A die-cast box about 50mm x 50mm x 50mm might do it if such a thing existed, and could be mounted without the lid by screws through the panel. Otherwise a box could be folded up from sheet aluminium. Re-visit the fuel sensor design and parts and check circuit values. Start to design circuit board layout. Order appropriate trimpot and buffer resistor from RS.
22 RS, Farnell & Parts For Aircraft orders arrive. Alas, some of the crimp terminals are not the preferred type with the metal sleeve extending over the wire insulation area. Reply received from Herr Schicke; he can supply the GR6 direct after he gets back from holiday in Crete. Sort out fuel sensor conditioning circuit and stripboard layout. Realise I need an extra resistor between the bridge and earth to prevent non-linearity. From Maplin get a 2k resistor and a plastic box YU52G 45mm x 54mm x 104mm for crowbar circuitry.
23 The fuel sensor conditioning circuit board will fit vertically in the slots in the wall of the Hammond 1591MBK box, but that will make the trimpot hard to reach. Order one with a side actuator, and some more red & yellow crimp terminals from RS. The terminals are a bit expensive as the minimum order is 100, but they are shown as having the desired metal sleeve extending over the wire insulation.
24 RS order arrives with the correct crimp terminals.

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