Thursday, February 28, 2019


We had a few nice days but winter came back.  I refilled my propane bottles so I could keep the shop warm.

Still futzing with the panel.  Also, I've been working on a throttle quadrant (reversing with friction lock) and will post photos later if it turns out functional.  Buying one is looking like the easy but more expensive solution.  I've got plenty of scrap 6061 so will see what my home made one looks like first.

Vance has bestowed a pile of his accumulated hangar stuff that he no longer needs upon me so I've spent at least three days sorting through about a gallon and a half of AN pipe fittings (some steel), assorted nut plates, clamps, bushings, spacers, screws and bolts.  There's still a bunch of stuff on the shelves to go through.

I dusted off X-plane to keep from getting to rusty.  I used one of the existing Cozy aircraft and tweaked the horsepower and prop.

Saturday, February 23, 2019

2019/02/23 Documentation

Most builders will check off and track their build progress in the plans.  This helps ensure no steps are missed and everything is completed.  During the last couple of years, I looked at some flying and project Cozy's and EZ's for sale.  Often the builders plans and logs were available, but occasionally there were no logs or no plans.   Someone that is not a builder would typically not have any idea what makes an aircraft the same or unique from others without this information. 

I purchased the EAA Air Frame log book, but with all of the additional mods with varying levels of complexity, decided the information needs to be organized better than piled into a box.  It is to extensive to try to cram into a single air frame log book.   The engine and props came with log books so they will remain separate, although it is not a requirement for an experimental aircraft.   When I'm ready for the inspection, I'll make some nice binder labels.   There's still some SkyView and Nav/Com operator manuals missing which I'll print and have spiral bound.

This is a work in progress but getting closer to completion.

Tuesday, February 19, 2019

Chapter 22 Tyco W31 Breaker Switch Special Airworthiness Information Bulletin

The type W31 Tyco Breaker Switches have a Special Airworthiness Information Bulletin CE-13-22.$FILE/CE-13-22.pdf

I was going to use these breaker switches for fuel pumps but am leaning towards traditional breakers and switches now since I'd be cycling these every preflight.

Chapter 22 - AC versus DC switches/ Documentation

Del City has some overstock toggle switches rated at 20 Amp AC for $.64 each.   I recalled that DC switches were often constructed differently than AC switches and found this informative article explaining the differences:

Switch Reference (An EATON training document hosted on the site)


It is important to also note that many AC rated switches can be used in applications where less than 30V DC is required, provided current does not exceed the full current 125V AC rating of the switch. In general, the 125V AC rating would be equivalent to the 28V DC rating."

The article is well worth reading.  Anyway, most of the switches I have will be used on low current resistive loads so isn't a factor.

I spent a good part of the day organizing a sizable pile of documentation for the engine, air fame & prop logs.  Binders were filled with specific information for modifications not in the plans such as the rudder pedals, site gauges, capacitive fuel probes, electric nose lift, hidden rudder bell horns, fuel injection, electronic ignition and quite a bit more.  This task was initiated because I was looking for information on the alternators and this turned into another rabbit hole, probably worthy of a separate blog entry sometime in the future.

I'll print out nice binder labels before the DAR inspection for the binders to replace the temporary sticker labels.   I still have a small pile of unique items that has documentation that will be needed someday.  Probably three more binders for avionics and electrical system will be added to these.  The small EAA Airframe log doesn't seem large enough to record everything.

Thursday, February 14, 2019

2019 02/14 More IP Panel

I happened across Brian Deford's web page today.  So sad to see what happened to his beautiful Cozy, but amazing to see how some people have the wisdom to find good in everything.  The charred remains of the Bible passage blew up to his feet with 1 Peter 4 verses 12-13: " Beloved, think it not strange concerning the fiery trial which is to try you, as though some strange thing happened unto you; But rejoice, inasmuch as ye are partakers of Christ's sufferings; that, when his glory shall be revealed, ye may be glad also with exceeding joy."

Despite several distractions today (it is Valentine's Day), I managed to get a little done and got some consultation on the panel.  It was recommended to insert the electronics into the trays and measure the gap between the tray and the bezel of the unit to determine whether the trays need to fit within the panel opening or if they can be flush with the back of the panel.   Then observe where the tray mounting screw holes are.

I moved the breaker switches out of the panel for now and think I may just put regular breakers in series with switches.   Currently, I'm leaning towards grouping the EI/EFI switches into Primary and Backup clusters so that if all of the switches are up, there is full redundancy.  Each group will have it's own master switch.  I think there's enough panel space to similarly configure the avionics and this will determine the final panel lay out.

One of my "long lost" orders arrived today, so I have "a few" other tasks I can go back and finish.

Considering this layout for full redundancy of the EI/EFI system.

Replacing the breaker switches with regular breakers solves the clearance issue but takes up more space for switches.

2019 02/13 Instrument Panel progress

This panel is the 2nd mock up (the first was 1/4" plywood).

The form factor of breaker switches (largest), breakers and switches becomes a factor due to clearance needed between rows.  The screws of the breaker's terminals are touching the breaker switches.  For simplicity and redundancy, I wanted to group these breakers and switches, but looks like I'll need to reposition them.

The glare shield limits vision, so the top row will be used for breakers that can be easily felt to ensure none are popped.   The second row (and third row?) is easier to see so makes sense to put switches and warning lights there.  The cluster of 4 breakers, two breaker switches and a toggle switch are enough to run the engine on a redundant fuel pump & ECU.   There is an identical cluster to the right for the alternate system not shown in the photo.

The switches to the left are some overstock 25 Amp switches with solder terminals used for mocking up the panel.   The white and blue circuit breakers are different values (2, 5 & 10 Amp).   The plungers of the circuit breakers protrude from the panel at a variance of about .1".

  Somehow, I cut the SkyView panels opening about .3" to wide.  The bezel covers up the gap, but I'll have the next panel CNC cut with the dimension corrected.

The odd component sizes mounted on the panel seems to be one disadvantage that the VPX system overcomes, although breakers are still needed for higher amperage circuits.

Tuesday, February 12, 2019

2019 02/12 Aircraft Reservation Renewal

We've been traveling, so not much work was done during the last week.   Checked on some parts that have been on order and found that Wicks had a "glitch" and had not processed my last order but should be on its way this week.   Also had a call from Aero Performance that the SCAT (cabin heat) tube I'd ordered back in December was finally in.   Odd that the 2 1/2" tube is the most expensive per foot and is what I needed.

In our pile of mail, there was a "Special Number Expiration Notice" card from the FAA, advising to go to    I poked around for awhile on the web site and was able to renew the reservation.

Here's a link for reserving N numbers on the FAA web site:

Saturday, February 2, 2019

2019 02/02 - Google+ shutting down

It appears Blogger and other Google services will be unaffected by Google+ shutdown.   Any comments made to blogspot from Google+ will be removed.   Fortunately, I don't have many entries made that way but have spotted some.   One of the issues of using a "free" service...