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05-17-2016, 11:07 AM
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Join Date: Jul 2014
Location: Madison, WI
Posts: 685
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Firewall passthroughs?
Trying to figure out the firewall passthroughs I will need for my RV-9A / IO-340 (FP prop.) Do any come with the Vans FW-FWD kit?
Looking at the Cleaveland options. I know I need two of the stainless passthrough kits (SA-05) for sensor wires, etc. I suspect I also need a number of eyeballs for control cables? Seems like they have Alum or steel? Also a different model but I can't quite figure out the differences or which ones to get (and how many.)
FPT1S or FPT1 or FPTTTP? I suspect Throttle, Mixture, Heater, Alt Air?
Also, what should I use to make the holes for the above? (and the heater hole.) I have seen people mention special mandrels that make those larger holes but they are quite pricey for something I will use once or twice per size?
Thanks!
__________________
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RV-9A - started 01/2015, completed 07/19/2018, 500hrs 03/14/2020
RV-10 - started 04/2020
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05-17-2016, 11:51 AM
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Join Date: Jan 2006
Location: Vonore, TN
Posts: 369
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Punch
For the larger holes, like the heater, find an electrician friend who has access to a Greenlee punch tool kit.
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John Tierney
Vonore, TN
RV-7A - N777JT Flying
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05-17-2016, 12:05 PM
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Join Date: Dec 2005
Location: Mahomet, Illinois
Posts: 2,195
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...OR find someone with a set of Rotabroach bits. They go thru the stainless firewall like the proverbial hot knife. The Rotabroach set is too pricey to buy; they're only practical if someone will lend them to you.
Some EAA chapters have a tool crib, in which case the Rotabroach set can be used by many.
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Terry Ruprecht
RV-9A Tip-up; IO-320 D2A
S. James cowl/plenum
(Dues paid thru Nov '18)
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05-17-2016, 12:23 PM
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Join Date: Jun 2012
Location: Hillsboro, OR
Posts: 63
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A more time consuming option: Try drilling a lot of #40 holes around the perimeter of the desired opening, then use a rotary cutter to remove the material between the holes. I know, it's a lot of drilling through steel, but a good bit with lubrication should make it slightly less onerous.
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RV addict for life.
NOTE: The information, ideas, and opinions presented in this post are my own and not those of my employer. Build, test, and fly at your own risk.
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05-17-2016, 12:44 PM
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Join Date: Mar 2014
Location: Laguna Hills, CA
Posts: 1,805
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Quote:
Originally Posted by RVTrumpet
A more time consuming option: Try drilling a lot of #40 holes around the perimeter of the desired opening, then use a rotary cutter to remove the material between the holes. I know, it's a lot of drilling through steel, but a good bit with lubrication should make it slightly less onerous.
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I did it this way too. I figured it was easier than chasing down a punch.
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Doug
RV-9A "slider"
Flew to Osh in 2017, 2018 & 2019! 
Tail number N427DK
Donation made for 2020
You haven't seen a tree until you've seen its shadow from the sky -- Amelia Earhart
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05-17-2016, 02:36 PM
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Join Date: Mar 2008
Location: Ramona, CA
Posts: 2,370
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I bought a set of punches from Harbor Freight and they worked just fine for the passthroughs (including all of the control cables).
Use a unibit to get the initial 3/4" hole started, then use the punch to enlarge this to 1 1/8" for the pass throughs. I used a 1" diameter pass through from Safeair1.com (no longer available).

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05-17-2016, 03:26 PM
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Join Date: Apr 2007
Location: -
Posts: 502
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Vans has a nice stainless firewall passthrough available now, FF-00001, for only $14.
David
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05-17-2016, 05:10 PM
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Join Date: Oct 2005
Location: Estes Park, CO
Posts: 3,947
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Passthru
Quote:
Originally Posted by digidocs
Vans has a nice stainless firewall passthrough available now, FF-00001, for only $14.
David
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Got any photos?
__________________
Larry Larson
Estes Park, CO
http://wirejockrv7a.blogspot.com
wirejock at yahoo dot com
Donated 12/03/2019, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
HS SB, empennage, tanks, wings, fuse, working finishing kit
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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05-17-2016, 10:28 PM
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Join Date: Oct 2013
Location: Schaumburg, IL
Posts: 5,297
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Unibits seem to work well on stainless. HF has a cheap set of three and the big one goes to 1.5", I believe. For the big heater hole, I roughed out the hole with a cut-off wheel and finished it with a carbide bit on the die grinder. Only took 20 minutes.
Larry
__________________
N64LR - RV-6A / IO-320, Flying as of 8/2015
N11LR - RV-10, Flying as of 12/2019
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05-18-2016, 12:10 AM
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Join Date: Apr 2007
Location: -
Posts: 502
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About 1" in diameter, stainless steel.
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