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Message-ID: <1703571977.m2f.512947@forums.matronics.com>
Subject: Europa-List: 181 Receives Planned Upgrades
From: "Area-51" <goldsteinindustrial@gmail.com>
Date: Mon, 25 Dec 2023 22:26:17 -0800
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--> Europa-List message posted by: "Area-51" <goldsteinindustrial@gmail.com>

Wow what an epic journey this one has been. After months of developing solutions and some failures along the way 181 has finally received its planned upgrades, entering a new level of fit for purpose.

Second AV-30 now fitted offering separate AH and DG appointment, completing the full traditional Six Pack. Also fitted Uavionix TailbeaconX ADSB Mode S ES transponder, Uavionix AVMAG magnetometer paralleled to both AV30's, Davtron OAT thermocouple sensor coupled to DG unit providing TAS DALT,  NMEA GPS Flight Plan data integration paralleled to both AV30's from Garmin Pilot III. AV30E latest firmware loaded to DG unit offering full flight plan graphical waypoint display. 30W 6chip LED landing/flight lights fitted at each outrigger station, new improved 3D printed outrigger speed kit cowlings fitted. Panel wiring cleaned up. New laser cut instrument panels fitted. New 3D printed GPS Pilot III mounting fitted. New trial 3D printed panel tags added.

It was epic. Lot's of stuff failed; even after successful bench testing. But quality assurance checks at various points identified faults and prevented catastrophe down the line.

The Garmin GTX327 originally selected worked great. The 2nd hand altitude encoder did not. After wasting hours setting up bench testing rigs it was decided more time efficient to just go out and order a new transponder. TailbeaconX proved a challenge on mounting it domewhere that did not look out of place. The middle flap horn cowling was selected. After ten failed 3D printed TBX mountings the eleventh passed all the requirements. The outrigger cowling took nine attempts to get right after finding left and right side factory cowlings are not symmetrical. That was solved with new fixing holes being drilled and the overal cowling width increased by 5.0mm for hassle free fitting and removal. Wiring was routed from the wing root cavity out along the flap cavity to both outriggers and secured with polyurethane. The 3D printed BeaconX housing was flow tested and returned 72g of excess drag.

Initial post bench test quality control of the panel wiring after fitting to the AC failed. Upon pulling the gyro fuses to save battery power faint sizzling was heard behind the main instrument panel. No guesses what the cause was going to be. One of the shit D-Sub connectors was experiencing high resistance voltage tracking (a high risk of panel fire existed at this point); they are a real shit connector solution and not even true milspec; a really disgraceful blight on modern aviation and I have no idea why they are still employed... So after ripping out both D-subs a whole day was spent making up two new connectors with much higher quality components and patching them in. Fire risk cut open inspected confirmed and thrown into the bin where it and all others like it belong.

Why use the Garmin Pilot III, its so out dated? GPS NMEA data protocol has not changed over the years, only the screen graphical display has. The Pilot III provides a horizontal vertical track guidance bar which can be used similar to ILS; a nice option to have allowing arrival at waypoint altitudes at desired rates of climb or descent and only seen now on very expensive units. Eventually this will assist in driving and monitoring an AP solution.

After nearly three weeks of solid unrelenting work and 12 hour days the lights finally went on at 10.30 last night; ready for op's. Waiting for ICAO Mode S  HEX code to be allocated.

That's all for now, wishing all a good and prosperous year!


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