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Dave's RV-10 Build Log
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Date:  12-11-2017
Number of Hours:  3.75
Manual Reference:  
Brief Description:  Air box Alternate Air Door and Drain Tube

Completed the engine air box alternate air door.

Had to cut the cable outer sheath to provide additional bare cable at the end in order to have bare cable crossing the door and secure the sheath at the right spot on the airbox with a cushion clamp per the drawings. Didn't find this out until I had bent the end of the cable with 3 wraps around the screw to secure the end to the door. To trim the sheath without removing the bent cable end, I used the Dremel tool with a metal cutting disk to cut along the length of the sheath, being carefull to not cut through to the inner cable. Then used diagonal pliers to separate the individual wraps of the cut sheath into rings. Used 2 pair of diagonal pliers to grab the 2 sides of each ring and bend them in opposite directions in order to open the ring and allow it to be removed from the cable. Used close nippers to cut the inner plastic sheath away from the cable after removing the rings.

Created a plug for the drain tube from an AN3-7 bolt. Held the threaded end of the bolt in a drill and ground the head down on the bench grinder stone (not the Scotchbrite wheel) until it matched the outside diameter of the tube. Then cut the threads off the bolt leaving the smooth upper shank to fit into the tube as a plug.

Glued the drain tube with plug to the bottom of the air box per the drawings using 4 layers of fiberglass with epoxy resin.
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