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Dave's RV-7A Builder's Log
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Date:  12-29-2014
Number of Hours:  3.50
Manual Reference:  
Brief Description:  Throttle cable

Today’s project was installing the throttle cable—something that ended up taking over three hours and still isn’t quite finished. In order to ensure that I had an acceptable firewall pass-through, I purchased an assembly that is similar to what we use on the certified piston aircraft that we sell. This assembly consists of a set of steel flanges that fit around an aluminum sphere that has been machined in two halves. When clamped together, and then screwed into the firewall bracket, the assembly allows for odd-angle firewall penetration without requiring a lot of messy sealer and the potential for leaks.

The first challenge of the day came when the brief instructions directed that a ¾” hole be cut in the firewall to accommodate the assembly. Since I had a step drill of that size, I elected to use that for the task. After drilling the requisite hole, and then adding the six holes for the bracket to attach, I spent a few minutes trying to figure out how this was going to work. For those of you actually reading this, you might notice that the template shows a 1 1/8” hole is required. When I finally reconciled that the template was indeed correct, I faced a dilemma…how to enlarge the hole? I brought out the hole punch and pondered the chances of severely bending (or worse) the area around the ¾” hole by using a punch that was barely larger than the existing hole, but in the end, I decided I had no other options. By carefully lining up the punch on the screw holes to ensure that I was indeed centered, I commenced to cranking it down, and to my surprise and relief, an almost perfect 1/8” circle popped out at the conclusion.

The next 30 minutes or so were spent adjusting the throttle body connections and making the initial fitting. There is a piece of firesleeve that goes on the throttle cable where it passes over the exhaust, but I’ll have to wait until that system is installed before I finalize that location. All in all, a fairly productive couple of hours.
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Template for throttle firewall pass through...note requirement for 1 1/8

Template for throttle firewall pass through...note requirement for 1 1/8" hole

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Finished assembly, still needs adjustment

Finished assembly, still needs adjustment

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Bracket attached at throttle body

Bracket attached at throttle body

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