Justin's Raven

Aircraft Projects Underway or Completed

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Jean Crous
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Re: Justin's Raven

Postby Jean Crous » Mon Jun 30, 2014 9:50 am

vhpy Justin I am sure you will MAKE it work ! This is also a good thread for folks that have an aircraft built by a company as mine, reading here they will soon see why things are not always what they seem in aircraft building :twisted: :twisted:
Good luck
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Re: Justin's Raven

Postby justin.schoeman » Mon Jun 30, 2014 11:21 am

JeanTree wrote:vhpy Justin I am sure you will MAKE it work ! This is also a good thread for folks that have an aircraft built by a company as mine, reading here they will soon see why things are not always what they seem in aircraft building :twisted: :twisted:
Good luck
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You can either save time (by, for example, ordering the full FWF kit from the US, or you can save money by buying what is available locally, and making it work. At least with composites, you only need to do it once. Once you have something that works, it is easy to pull a mould and do it again ;) .
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Re: Justin's Raven

Postby justin.schoeman » Tue Jul 01, 2014 12:11 am

I really need to get to the airfield to do the final fitting of the instrument panel and airbox, so that I can finish those off. Also need to strip off the gascolator and stiffener so I can start moving them. With any luck, I will be able to take leave on Wednesday to do this, and start making real progress again.

Until then, I have just been finishing off some small bits on the instrument panel.
rps20140630_230623.jpg
Mechanically pretty much complete now. Just need to do the final trim and fit so I can finish it off. Seems to be working quite well so far. And those wooden cabinet knobs seem to make quite good looking throttle knobs ;) .
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Re: Justin's Raven

Postby avgas » Tue Jul 01, 2014 6:44 am

Well done (^^) (^^)
That is the way I remember the EAA and Homebuilding fraternity. We spent hours tinkering and improving our planes :wink:
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Re: Justin's Raven

Postby bobthebuilder » Tue Jul 08, 2014 9:44 pm

Wonderful Justin.
A natural born tinkerer!

As a matter of interest, have you weighed the instrument panel?
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Re: Justin's Raven

Postby justin.schoeman » Tue Jul 08, 2014 10:25 pm

bobthebuilder wrote:Wonderful Justin.
A natural born tinkerer!
Personally, I would prefer to be flying - but the VW experiment did not turn out as I would have hoped...
As a matter of interest, have you weighed the instrument panel?
1.7kg with all sub panels, and the throttle mechanism included. Pretty much the same weight as the original equipment, but much easier to maintain (and prettier ;) ).

Note that it is not carbon fibre - there is a single layer of carbon on the outer surface as an (failed) attempt to make it look pretty. I was originally planning to make it completely out of carbon (much lighter), but an aeronautical engineer friend got a very startled look and said 'You can't do that!' when I mentioned it... CF in front of the pilot is a very bad idea, as it shatters with very sharp edges in an accident. So it is mainly glass fibre, with the one decorative carbon layer (and now a layer of CF look vinyl over it).
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Re: Justin's Raven

Postby bobthebuilder » Wed Jul 09, 2014 6:24 am

It looks really nice.
I'm sure that wasn't a one week job.
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Re: Justin's Raven

Postby justin.schoeman » Wed Jul 23, 2014 4:25 pm

Even though I have done it before, it still got me... The seemingly endless number of small tasks involved in even a 'simple' change like this.

So far, I have most of the FWF bits and pieces finished, and ready to install.

I have also stripped most of the old FWF stuff, and blanked of the old holes in the firewall. Most of the new stiffeners are fitted, as well as the gascolator and air guides. Most of the fuel plumbing is done, but I still need to remake one pipe for the new gascolator position. Still need to fit the air box, battery and relays.

Here are some pics of the progress so far.

Finished (hopefully) airbox (serious cut-and-paste hob here):
rps20140723_123514.jpg
Engine with oil cooler fitted, rivet flange for oil cooler duct and nearly complete ram-air ducts:
rps20140723_123651_564.jpg
Instrument panel with all mechanical bits, and avionics powered up. Still need to add 3 airframe connectors and radio panel:
rps20140723_123733_940.jpg
The disaster zone behind the panel. Using a sub-frame for the main electrical connections is probably a good idea - but it does get a bit busy. Decided to do away with all the steam guages - so it also has a backup battery and charger. Xtreme is on a separate electrical bus with battery backup.
rps20140723_123820_664.jpg
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Re: Justin's Raven

Postby justin.schoeman » Thu Jul 24, 2014 11:08 am

Last night I was trying to work out where all the time goes. Each evening, I work 2-3 hours in the garage (engine and fitment), and another 2-3 hours inside (instrument panel). And yet, I don't really see much progress.

So I made some notes last night. Got into the workshop at 19h30, and worked there until 22h10 (2 hours and 40 minutes). Started by finishing the fit (trimming internal baffles) on the right air duct. Then marked and drilled the mounting holes. Discovered that two of the holes were extremely close to the edge, even with the ducts flush against the tappet covers, so decided to add some reinforcing tabs to make sure they can't tear loose. Measured up, cut, drilled, filed and sanded 6 tabs, as well as 2 spring brackets. Floxed and riveted all 8 in place.

Total time 2 hours and 40 minutes, and I covered exactly one page from a 83 page installation manual...
Attachments
rps20140723_215110.jpg
8 brackets - cut, drilled, filed and sanded
rps20140723_215210_485.jpg
Floxed in place
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Re: Justin's Raven

Postby JvTonder » Thu Jul 24, 2014 12:22 pm

Nicely done Justin. You know what they say when one's plane is 90%complete then 90% remains, now we know why vhpy
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Re: Justin's Raven

Postby justin.schoeman » Fri Aug 01, 2014 2:53 pm

Some belated updates. Slow (but steady) progress being made.

Just about done with all the goodies that go on the firewall behind the engine. All of the old holes plugged, and new fittings in place:
rps20140730_222440_836.jpg
Test fitting panel - mainly for cable lengths and routings. All still looking good.
rps20140730_222511_799.jpg
Busy with AVDALSR085 - I hate the CHT sensors under the plugs... Unfortunately, my mains powered Dremel packed up, and my battery powered one only has enough juice to do two heads at a time...

First remove plugs and head bolt, and (thoroughly) cover the holes:
rps20140801_141842.jpg
Now viciously assault it with the Dremel, until the CHT probe fits snug against the head. Tap and drill the hole, and presto:
rps20140801_142030.jpg
Finished product:
rps20140730_222633_325.jpg
Testing the CHT probes by heating the bolt, to see how accurately/reliably these little lugs conduct heat to the thermocouples:
rps20140730_222732_362.jpg
While heating them, you can see a little lag. The sensor closest to the flame picks up quickest, and the ones at the other end also pick up quicker (direct contact with the head of the bolt), but the heat does conduct fairly well through the entire stack:
rps20140730_222814_221.jpg
rps20140730_222814_221.jpg (38.02 KiB) Viewed 897 times
Wait a few seconds after removing the flame, and all six senders match exactly:
rps20140730_222918_744.jpg
rps20140730_222918_744.jpg (44.66 KiB) Viewed 897 times
Basically, I would say the sensors all work perfectly, and track the actual bolt (soon to be cylinder head) temperature within seconds.
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Re: Justin's Raven

Postby justin.schoeman » Fri Aug 08, 2014 4:06 pm

OK - Installing the engine tomorrow! I think everything is pretty much done. All the cables are made up, and tested. Probes and senders fitted. Exhaust (almost) fitted. Wiring (mostly) complete.

There will still be a bit of work to do once the engine is in, but at least it will be on the plane...

Cowl jigs made up to space and align cowl to prop/spinner:
rps20140808_155204.jpg
rps20140808_155204.jpg (28.52 KiB) Viewed 854 times
I noticed a mismatch between the ASI on the Ultra and Xtreme, so I converted a table leg to a water manometer to do the calibration:
rps20140808_155344_374.jpg
rps20140808_155344_374.jpg (16.93 KiB) Viewed 854 times
Turns out the Ultra was spot on, but the Xtreme was off. Seems someone did a factory reset on the Xtreme, and wiped the calibration. Calibration now set, and both agree with the water manometer from 0-100kts.
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Re: Justin's Raven

Postby justin.schoeman » Tue Aug 12, 2014 10:29 am

No pictures from Saturday - I was way too busy, but a friend did get some, and I will add them when I get a chance. The engine is on the airframe now, and mostly hooked up. Everything is looking good, except for the top cowl, which is 50mm too short (Raven front fuselage-firewall intersection is different from the 601).

Will be ready soon!
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Re: Justin's Raven

Postby justin.schoeman » Mon Sep 15, 2014 10:07 pm

Wow - I have been very lax in posting updates recently. Between customers baying for my blood (or at least for my work-product) at work, working 3-4 hours every evening on plane parts and 8+ hours every Saturday and Sunday, I have not had much time.

Fortunately, tonight I am absolutely stuffed from squash training, and don't actually have much to do on the plane, so I will spend some time posting the updates.

As usual with this sort of work though, there is a lot of work, with very little to show for it, but here it goes anyway...
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Re: Justin's Raven

Postby justin.schoeman » Mon Sep 15, 2014 10:19 pm

First, fit the cowl, with clamps, centring everything on the prop hub, and positioning with fibre tape:
rps20140915_201703.jpg
rps20140915_201822_229.jpg
Once everything looks good, the bottom cowl is drilled, and screwed to the fuselage (you can also see how the top cowl has been extended - by Arthur - so that it now fits):
rps20140915_201946_631.jpg
Once that is all done, the top cowl is trimmed to fit flush, then bonding/reinforcing strips epoxied in, hinges flocked and riveted in place, joggles formed, and NACA duct cut in and bonded. One sentence that took a solid week of work to complete...
rps20140915_202434_205.jpg

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