Europa #435 G-RODO Build Journal - 2012 09

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2 At LAA Rally, get a couple of switches from LAS Aerospace that could be used for PTT, also some Duralac and a couple of 1N5408 diodes to go across starter coil, and a couple of reduced-price lifejackets. See Neville Eyre's new cowl displayed in the homebuilders tent.
4 Cut stripboard to size and build most of fuel level sensor conditioning unit. Find that Maplin sold me a 1k instead of 2k resistor so will have to get another one. Check again how the crowbar stuff will fit in the PX1 box and decide it will be just too tight to get it all in. Order a bigger box and a 2k resistor from Maplin online.
5 Send e-mails to Neville Eyre about his new cowl and to Utz Schicke about ordering the GR6 regulator.
6 Neville Eyre replies confirming price of his cowl with info about cooling options and saying he can do a set within a couple of weeks. Schicke pro-forma invoice received for GR6 and Swift bank transfer initiated.
11 Having decided that I won't need 999 different wires in each functional category, change wire labelling system from 1001, 2001, 3001, etc to 101, 201, 301 etc and edit all files as necessary to match. Finish building fuel level sensor amplifier circuit, adding the 2k resistor and the wire straps in 24AWG Raychem 44. Make holes for sensor tubing and for leadout wire grommet. Find that the red crimp terminals won't hold on 24AWG, so add the flying leads in 22AWG Raychem 55. Mark the wires with paper labels (Helvetica 8 on paper strip about 3mm wide seems the right size) under clear shrink-wrap before final termination. Add a tie-wrap on the board to support the leads away from the solder connexions.
13 Schicke GR6 regulator & order from Bob Nuckolls arrive. The 1-way fuseholders tails are 12AWG which is bigger than I expected - hadn't read the website description properly! Draw up the MGL FF-1 connexions in CADintosh and add the fuel level sensor wire IDs.
16 Order some 22AWG Raychem 55 and some red butt crimps from Farnell.
19 Collect Farnell order from sorting office.
20 Look in detail at the layout of the box for the crowbar components. Sketch out how everything should fit, and where double wires will go in crimps. Add terminal identification of relay & crowbar to main circuit diagram.
21 The 0.5A fuseholder for the alternator warning LED could usefully go in the same enclosure as the crowbar stuff. Amend box outline on main circuit diagram to show that. Find I've got a 5mm x 20mm RS fuseholder in stock, but not a 0.5A fuse to fit. Could get that from Maplin, when they get some in stock. My fuseholder has solder tags; check the RS item called out in the mod document and that has solder-tags too. Will need to support the outgoing wire to avoid stressing the solder joint - probably tie-wrap a short lead to the fuseholder body with a flying blade connector for the external connexion. Check engine package for capacitor and find none, so order from Farnell. Can't decide which of the 2 found is best so order 1 of each, and some 0.5A fuses.
22 Amend main circuit diagram to include CSC-1 pitch motor brush connexions. Cross-check with instrument documentation for fuse ratings and amend main circuit diagram as appropriate. Add fuse rating field to load analysis file. Start to draw up CSC-1 propeller controller connexions in CADintosh.
23 Order (from CPC) clip for 50mm dia capacitor & cordless oscillating saw. Notice that Smart Avionics circuit diagram for Woodcomp prop shows 10A fuse rather than the 3A shown on the Woodcomp documentation. To avoid unwanted outages, better use 10A fuse; change load analysis file entry & main circuit diagram to show that.
24 Capacitors & fuses arrive from Farnell. Check the instrument module F14 again for possible fuseholder locations. Looks as though the 3 main fuseholders would fit comfortably under the shelf. The whole shelf could be cut out for an access panel.
25 Check terminations for UMA tachometer (4 flying leads) & hourmeter (1/4" male blades). Note that tacho documentation calls out a 270 ohm parallel resistor, compared with the 220 ohm for the E-3 tacho input. Edit main circuit diagram to show 270 ohm adjacent to the UMA tacho. Edit CADintosh circuit diagrams for CSC-1 and E-3.
29 Check the tubing for connexion to the differential pressure sensor for the fuel gauge. It seems quite tight - will need some care in assembly to avoid possible damage to the sensor & circuit board! Also there is not enough spare length to take the other side of the sensor to the vent at the top of the sight gauge. Will need to get some more of that tubing, wherever it came from.

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