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  #21  
Old 12-30-2020, 07:00 PM
agent4573 agent4573 is offline
 
Join Date: Aug 2019
Location: Mountain view
Posts: 365
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Finished up the canopy fairing. Like the rest of my fiberglass, it's not perfect, but it fits great and is plenty good to go to the painters. I also got the main gear on and hung the engine. The instructions for the gear are a single line that basically say "this can't be easier, tube goes in hole and a single bolt". After some blow torches and ice bath, lots of sanding, making a drift pin and bending said drift pin with a 4lb dead blow, and hours of fighting it, the gear went in. Great job on the instructions vans....
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  #22  
Old 04-14-2021, 07:00 PM
agent4573 agent4573 is offline
 
Join Date: Aug 2019
Location: Mountain view
Posts: 365
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So after months of waiting for parts, things started happening very quickly. I've been on hold since December waiting for a cowl from Sam James that was supposed to arrive in November. The moderators will not let me go into any details about this. What I will attempt to say, is that the new owner of Sam James cowling (Mona) has been a pleasure to work with and is extremely accommodating and customer focussed. The old owners I'm not allowed to talk about. Skipping ahead.....

Last week the panel showed up from Aerotronics. With only very minor trimming of the lower panel brackets, a hole for the radio and GNX375, and minor trimming of the center vertical to clear the AP control head, the panel bolted in. Now the only thing left is to wire the rest of the plane. Minor detail.

Next is the box with the cowl in it. The quality of it looks really good. Not sure how much final work will be to fit it, but I'm looking forward to getting it on the plane. I also got their plenum and FAB for the full setup. The alignment tool is in the mail from Blake at Flyboy accessories. I ended up buying the tool, so if you need one in the bay area later this year, shoot me a PM. I was planning on getting with the local EAA chapter and letting them borrow it long term once I was finished with it.

And finally, we have a delivery from Whirlwind Aviation. Here is a brand new 300-72 prop. Saber delivered the 2.5" CS extension a few weeks ago and I think everything is finally here to get a majority of the FWF finished.

In my downtime I started training for my IFR ticket. My checkride is scheduled for May 1st, and after that I'll be diving back into this build hard.
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Last edited by agent4573 : 04-14-2021 at 07:04 PM.
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  #23  
Old 04-15-2021, 06:27 PM
motodave motodave is offline
 
Join Date: Dec 2018
Location: Littleton, CO
Posts: 90
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I've been waiting on my James cowl for quite some time. Mona called a couple of days ago, she is very helpful and they may be light at the end of the tunnel for me soon. I was getting very concerned as I bought the extended hub Hartzell CS prop specifically for that cowl... a expensive piece of kit and a special order M2YR. My M1B TB engine arrives by EOM (I'm told) and then I will want the cowl to start fitting it to the fuselage, prop, spinner.

Was your cowl a product of the new/current James team?
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RV7 Slider N732DH reserved
I(O)360-M1B Thunderbolt
Empennage 100% Complete
Slow build Fuselage 95% done
Wiring 40% done
Was QB wings now will be slow build...
Littleton, CO
Photo log: https://flic.kr/ps/9jjZz
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  #24  
Old 04-16-2021, 11:37 AM
agent4573 agent4573 is offline
 
Join Date: Aug 2019
Location: Mountain view
Posts: 365
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The cowl I ended up receiving came from Mona and the team in Texas. Yeah, that extended hub prop really locks you into using their cowl. Hopefully she gets you one soon. I know for a fact there's an extra RV7 long cowl sitting in a shipping dock in maryland right now. If you're next in line it may be available sooner than you think.

When she first took over earlier this year she was waiting on some back ordered material before she could even start manufacturing. I'm sure they're doing what they can to catch up, but she was on pause for at least 2 months waiting for supplies. I think my original order for the cowl was placed february or march of last year.
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  #25  
Old 07-31-2021, 06:44 PM
agent4573 agent4573 is offline
 
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Location: Mountain view
Posts: 365
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Sitting here at Oshkosh with some down time and figured I'd write a mobile update. Got the cowl done, but not without a lot of finish work. I used the cowl alignment tool, followed Sam James instructions and still managed to have a 1/2" gap across the front when I removed the tool. I did get to test fit the prop just to verify the distance to set the tool, so that was a happy day. I went back and added a flange and some flox to close the gap up and it looks good. We went with the skybolt fasteners and I started off by dimpling the flanges instead of countersinking them. Since everything had been match drilled by that time, I decided to make spacers instead of ordering new flanges, so I now have 50+ .063 spacers as reinforcements on my cowl mounts. Beyond that it was filling and sanding, rinse and repeat. Got the cowl in primer just before we headed out to Oshkosh on the 16th. We went with the spring loaded oil door hinge and glassed in all the cowl and door rivets with a layer of fabric and then micro. We're running a plenum for cooling, so I didn't feel the need to reinforce the quarter turn line or the oil door for strength. If we were using the standard baffle kit, I likely would have put a layer or 2 of carbon inside the oil door and along the fastener line.
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Last edited by agent4573 : 07-31-2021 at 07:21 PM.
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  #26  
Old 07-31-2021, 07:04 PM
agent4573 agent4573 is offline
 
Join Date: Aug 2019
Location: Mountain view
Posts: 365
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Along with the cowl, we've been working on adding extra fire protection to the firewall. We went with 1/8th fiberfrax and .005 stainless sheet with firebarrier 2000 to seal the edges. I added plate nuts for most of the things that might have to come off more than once, and made a tray to mount the 2 gps antenna. We drilled all our pass throughs and hopefully I didn't forget any, but I'm sure I did. We're running dual throttle/prop side quadrants so we got those mounted on the classic aero side panels and sent them in for fabric after we ran our dual cables and got the mounts figured out. We ended up having to trim a bit off the right side panel in order to better hide the smoke oil line that's running along that side of the floor.
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Last edited by agent4573 : 07-31-2021 at 07:28 PM.
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  #27  
Old 07-31-2021, 07:41 PM
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Vlad Vlad is offline
 
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You are very meticulous Paul good job! I would suggest to replace the cable end caps (stock black rubber) with newer ones they are blue. You still have a good access. It will save you headache several years later. Mine cracked and disintegrated after about 400 hours.

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  #28  
Old 07-31-2021, 07:45 PM
agent4573 agent4573 is offline
 
Join Date: Aug 2019
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Quote:
Originally Posted by Vlad View Post
You are very meticulous Paul good job! I would suggest to replace the cable end caps (stock black rubber) with newer ones they are blue. You still have a good access. It will save you headache several years later. Mine cracked and disintegrated after about 400 hours.

I'll put a couple sets on my next spruce order. Thanks for the info.
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  #29  
Old 09-06-2021, 09:32 PM
agent4573 agent4573 is offline
 
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We have the firewall accessories mostly mounted at this point. The right ignition box was damaged during the first engine install attempt and I never ordered a replacement. Luckily the SDS uses an off the shelf suburu box, so I've not got a replacement coming from Rockauto for like 60 bucks.

Got started on the baffling and took a while to trim everything to fit the contour of the engine well. I used the prettybits site to find the ECI taper fin baffle extensions and made up all four to fit the shape of the ECI tapered cylinders I have on the engine. I've attached the pdf in case prettybits site every goes down. I also took the time to make my air dams removable so if I have to tweak the size/shape of them to equalize cooler later, its as simple as 3 #6 screws and they come right off to me trim or remake.

I tried to fit the Sam James plenum for a trial fit, and it didn't go well. Large gaps around every edge, the Sam James plenum is not designed to fit over the injectors that the SDS system uses. In order to get the plenum low enough to have 1/2" clearance from the cowl I had to cut some major holes in it. The flanges also didn't line up close enough to actually seal to the baffles either, so I ended up hacking the plenum up pretty bad before I could make it fit. The entire rear flange came off and the rear passenger side corner got completely cut off in order to change the angle to clear the ShowPlanes 13 row dynafocal mount oil cooler opening. We tried to take the entire baffle off in order to layup the new rear flange but it didn't work great. The baffles shifted position over night and the rear flange didn't come out 100% where I wanted it. If you're going to do this, you really need to make a box out of wood to hold the plenum in the proper position while the fiberglass cures.

Once the rear flange was replaced, it was time to take care of the bump-outs to clear the fuel injectors and lines. This was done on the plane to make sure everything came out correctly. I laid tape over the top of the injector lines to protect them, then used play-dough to build up a 1/4-1/2" clearance. I covered the play-dough with a layer of aluminum tape, waxed it up, and laid a few layers of glass over the top of that. The hardest part of was doing the cleanup on the inside afterward since I had to open the holes and fare them into glass that I just laid on the topside. Not a big deal, but I did go a little hard with the dremel and had to put a few extra layers of reinforcement on to cover the holes I sanded into the plenum. I also put some glass inside the round inlets to make the transition from the plenum to the metal baffles. Keeping the air dam and front portion of the baffle there made it pretty simple to transition from the fiberglass to the metal with an easy, almost airtight seal. After that, I used some flox to seal the corners and then hit it with a layer of micro just to smooth it out.
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Last edited by agent4573 : 09-06-2021 at 09:42 PM.
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  #30  
Old 09-06-2021, 09:40 PM
agent4573 agent4573 is offline
 
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More pics.....
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Last edited by agent4573 : 09-06-2021 at 09:44 PM.
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