Wings, Systems Routing (Part 4)

During today’s session, I focused on the last two “routings”.....the Wing Tip landing lights and the static lines for the Dynon Pitot Tube (heated with AOA).

To begin, pictured below are the Aeroled’s Aerosun VX landing/taxi/recognition lights designed for the RV line of aircraft.  These lights draw 60 watts of power and generate a combined 13,300 lumens of light.  The lights include a built-in wig-wag controller for a synchronized recognition light mode.  These are additional/optional lights that I have chosen to add to the my lighting system.  These lights will work in conjunction with the Aeroled Sunspot 36’s that will be installed in the outboard leading edge of each wing.

The fairings (known as a conversion kit) shown below were also ordered with the lights.  This conversion kit is required to enlarge the lighting cove to accept the Aerosun VX lights.  This conversion kit is required for the RV-10 and RV-14 if the Aerosun VX will be used.  (This installation will be covered at some point later when I complete the fairing work).

Here’s a video of the “extra” landing light wire run in the Right Wing.  (I will show the Left Wing static sine runs further down the post).

With the additional landing light wires run and completed, I started working on the Static Line runs.  My airplane will need/use three static lines.....

Blue tubing:  Airspeed (Dynon Pitot Tube)

White tubing:  Angle of Attach (AOA) (Dynon Pitot Tube)

Red tubing:  Static Ports 

The blue and white nylon 1/4” O.D. tubing is shown in the packaging and the red is already installed in the Aft Fuselage (as shown below).  All three were ordered from Cleaveland Aircraft Tool.

Because I am adding the additional Wing Tip Lights and two Static Lines (Pitot and AOA), I had to “modify” four of the Left Wing Ribs.  When I was preparing the Ribs in an earlier section, I drilled 1/2” holes in them to allow for wire and tubing runs.  In the picture below, two of these holes are circled and have plastic grommets installed.  The bottom bundle of wires are for the leading edge landing light (Sunspot 36) and the position/strobe light (Pulsar NS90).  The two white wires are for the optional Aerosun VX landing lights.  The two holes that are circled are to be used for the Pitot static lines.  Since I’m using the Dynon Pitot tube with AOA, I will need to use two static lines.....and two static lines WILL NOT fit through the 1/2 hole.  I debated several different options, but ultimately decided to enlarge the holes on the four associated ribs.

The original holes were drilled to 1/2” and needed to be enlarged two steps on the unibit to 5/8”.  Shown here are the four holes I enlarged.  The holes were then deburred and treated with Alumiprep, Alodine, and Akzo Primer.

After the Akzo Primer dried, I installed these MS-35489-13 rubber grommets.....

.....and “tested” to ensure the proper fit.

After the “test” fit I ran the tubing.  Here is a close up of the tubing installed in the Left Wing with showing the rubber grommets. 

This picture shows the final installation of the static tubing.  The plans called for the tubing to be cut to 8’ lengths.  I cut them to a little over 9’ just to make sure there is enough extra if it’s needed.

Lastly, here is a video showing the installed Aerosun VX wiring and blue/white static tubing.  You can also see the wiring for the ADAHRS, Sunspot 36, and NS90.

Section Complete

Wings, Systems Routing (Part 3)

During today’s session, I ran the wiring for the WH-00012-ADAHRS in the Left Wing.

Pictured below is the wires and harness in the packaging from Van’s.

Here is the initial installation of the wires.  The far left side of the wires are coiled (I used the orange tape) for later connection to whatever ADAHRS system I choose.  (I plan on using Dynon Avionics).

So, that is all the wire runs for the Systems Routings (well, almost).  I still have to run tubing for the pitot tube.  However, I am waiting for the Dynon pitot tube to arrive.  Once it does, I will install it and complete this section.  I will be using a heated Dynon pitot tube with AOA.

So, I’ll “pause” Section 19 until I start the Pitot Tube install.

Wings, Systems Routing (Part 2)

Not much excitement today.....I ran the wiring for the WH-00013-AP Servo during this session.

Wings, Systems Routing (Part 1)

I’m currently waiting on my friend Jeff to help me finish the Fuel Tanks.  I will definitely need his assistance to install and rivet the Ribs (with the Proseal).  So, in order to keep moving forward, I’ve decided to start on the Wing Systems Routing section.  

Below, are the Wing Tip Lighting Harnesses for the Left Wing (top picture) and Right Wing (bottom picture)

The first step is two label the Harnesses (C400P and C401J) appropriately as shown below.  To do this, I just used a regular label making machine, so nothing special here.

The two pictures below show the Wing Tip Lighting wire runs for the Left Wing.  The first picture shows the mid-wing area where the wires “shift” from one row of bushings to another.  The second picture shows the Wing Tip where the wires run to two different locations.....to the Wings Tips for navigational lights and strobes and through the spar for the Landing Light.  

The two pictures below show the same Wing Tip Lighting wire runs and locations, but for the Right Wing.

Lastly, here is the origin of the Wing Tip Harnesses for the Left Wing (on the left) and Right Wing (on the right).  The black and white wires under the orange tape will be installed/connected once the Fuel Tanks are completed and installed on the Wings.  The white wire will be run through the small bushing in the Main Spars to the Fuel Level Senders and the black wire will be a ground connected to the first Wing Ribs.

I will obviously need to “clean up” the wire runs, but will do that at the end to make sure all the wires are installed properly.