--> 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!
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=512947#512947
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