One of the things I appreciate most about building an experimental aircraft is that I can pursue my own solutions to problems, especially of the problem was caused by my own error.
I was installing the cabin floor covers that ran between the fuel boost pump/fuel tank valve and the firewall. This covers the wiring and the main fuel line. The Center Cabin Cover (part F-781C) runs forward along the floor to the firewall, then turns 90 degrees upward to cover the footheat air valve. When I installed all the aircraft wiring that runs through this area, I was supposed to have given the wiring enough slack to run all the forward to the firewall, then make the turn 90 degrees upward.
I GOOFED! I didn't give the wire enough slack, and the center cabin cover can't seat all the way forward to the firewall. Options:
1) Try to 'fish' some more slack out of these wires, putting them under strain.
2) Do a whole mess of cutting/splicing...out of the question.
3) Create some room by letting the wires 'cut the corner' on their way upward.
I chose option 3: Just create more room for the wiring.
I fabricated a 45-degree channel from scrap aluminum. This 45-degree channel consists of two sides each cut as a right triangle with 3" legs and a 4.25" hypotenuse. Yes, this means I got to actually apply Pythagorean's Theorem (although I guess I could have just used my angle to draw a right triangle with 3" legs, then connect the ends, but that would be too easy...sheesh!).
I riveted these together with AN426-AD3 flush rivets, and added two end flanges with screw holes.
I assembled the center cabin cover to the F-982E access cover, then marked the cut lines for my newly fabricated angle channel.
With the channel hole cut into the center floor cover and access plate, I cleaned up the edges, drilled and installed K1000-8 plate nuts for the channel cover, then painted.
I installed the center floor cover and ran the wires and fuel line for zero stacking and interference.
I then installed the access plate to ensure there was no edge interference in the new hole at the 90-degree turn.
Finally, I screwed the 45-degree channel cover into place, then completed the center cover installs. I feel pretty proud of this, and chalk it up as one of the joys of experimental aircraft building.
Keep Calm and Build On!!
I was installing the cabin floor covers that ran between the fuel boost pump/fuel tank valve and the firewall. This covers the wiring and the main fuel line. The Center Cabin Cover (part F-781C) runs forward along the floor to the firewall, then turns 90 degrees upward to cover the footheat air valve. When I installed all the aircraft wiring that runs through this area, I was supposed to have given the wiring enough slack to run all the forward to the firewall, then make the turn 90 degrees upward.
I GOOFED! I didn't give the wire enough slack, and the center cabin cover can't seat all the way forward to the firewall. Options:
1) Try to 'fish' some more slack out of these wires, putting them under strain.
2) Do a whole mess of cutting/splicing...out of the question.
3) Create some room by letting the wires 'cut the corner' on their way upward.
I chose option 3: Just create more room for the wiring.
I fabricated a 45-degree channel from scrap aluminum. This 45-degree channel consists of two sides each cut as a right triangle with 3" legs and a 4.25" hypotenuse. Yes, this means I got to actually apply Pythagorean's Theorem (although I guess I could have just used my angle to draw a right triangle with 3" legs, then connect the ends, but that would be too easy...sheesh!).
I riveted these together with AN426-AD3 flush rivets, and added two end flanges with screw holes.
I assembled the center cabin cover to the F-982E access cover, then marked the cut lines for my newly fabricated angle channel.
With the channel hole cut into the center floor cover and access plate, I cleaned up the edges, drilled and installed K1000-8 plate nuts for the channel cover, then painted.
I installed the center floor cover and ran the wires and fuel line for zero stacking and interference.
I then installed the access plate to ensure there was no edge interference in the new hole at the 90-degree turn.
Finally, I screwed the 45-degree channel cover into place, then completed the center cover installs. I feel pretty proud of this, and chalk it up as one of the joys of experimental aircraft building.
Keep Calm and Build On!!
