NACA inlet

The NACA inlet opening should be 1.5" wide per Terry Schubert.

Irwin razor saw.

NACA after opening up the inlet to 1.5".   

Nose wheel bearing preload

The nose wheel bearing race should not spin on the axle.   The spacers needed a few thousandths shaved off the inside surface and each measures at about 1.752" thick.   Starting thickness was closer to 1.755".

Mike Arnold's Moldless Wheel Pants

YouTube video:
Mike Arnold's Moldless Wheel pants

Polished Nose Gear

120 grit, then 180 grit bristle Dremel wheels were used.  Then filed off the high spots with a small fine file, hit with the wheels again, then polished multiple times with Mothers Mag & Aluminum Polish.  

I asked for suggestions and replies ranged from "leave it as is", "powder coat it" or polish it.

Eureka Leg fairings

The foam cores were cut into 3" sections in order to follow the curvature of the leg.

Pour foam (.5 oz Part A and .5 oz Part B) were mixed and spread on the leg then the inside pieces were pressed onto the sticky foam.

Nose wheel pivot assembly/fork polish

The MKNG-15 and MKNG-16 are sand cast aluminum.   I've inquired about polishing these and ordered some abrasive accessories for a Dremel.

After some light filing, 120, 180 grit and aluminum polish.  About 5 hours of work.

The spherical bearings are not protected by a boot.

There are some machined spacers to limit the preload on the bearings.

This Teflon seems like an optimal lubricant and corrosion inhibitor for the spherical bearings since they're not protected by a boot.

Flipping the bird

1/2" plywood, a heavy locking castor wheel, strap iron were used to make a dolly.

It took 4 adults to flip the bird.  A strut between the seat back and castor wheel was added for additional strength.

Chapter 24

Canopy on the bench.  Covers for landing gear, landing brake actuator, nose, instrument and battery. Glare shield,  armrests, seats and rear air duct.

Chapter 22 Battery tray and strap

I used 4 mil plastic, peel ply and 4 layers of 6x9 BID with cuts to allow folding on the corners.   Box tape over cereal box cardboard on the battery.

1" mark was scored with the bandsaw, then used the Fein tool to finish the cut.

The PC680 battery sets back about 2" from the face of the spar.   The flox fillet on the inside of the firewall doesn't allow the battery to be flush against the back so a 1/4" foam will help secure the battery.

.062 x 2"  2024T3 strap was made.   Another strap for the firewall side with nutplates was made.

Bending metal - set back, bending allowance

Worth watching if you plan on bending metal much.

https://youtu.be/HemwD3NpKXk

Relay Coil Noise Suppression - Zener diodes

Relays with regular diodes across the coil take almost double the time to open than without a diode.  The life of the contacts is shortened and have higher risk of tack welding together.    Better alternatives are resistors, zener diodes, snubber circuits or no suppression.



https://pickercomponents.com/pdf/application%20note/Coil_Supression_vs_Relay_Life.pdf