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Dave's RV-7A Builder's Log
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Date: 4-29-2017
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Alternate air cable and other finishing tasks
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There are still a lot of little tasks that need to be finished before it’s time to fly, so today I focused on getting everything firewall forward completed—everything except the cowling and spinner anyway. I started by installing the alternate air cable and securing it in the sub panel in the cockpit. I had previously fitted the cable and tested the functionality, but was never really satisfied with the fact that the door only opened about halfway. Since there is only about a two inch travel of the actuating wire, the clamping location becomes the primary focal point of the assembly, so I spent some time fiddling with the spacing. I would go to the cockpit, pull the knob fully open, check the location of the door, and then repeat with the knob fully stowed until I found the spot that was most effective. Once that was done I had the challenge of bending the wire (very stiff and springy) to wrap around the screw in the door. I ended up using some heat from my torch and bent it around a drift pin to get the loop as close to the end as I could.
After finishing that, I made some standoffs from nylon brake line tubing and secured the CHT and EGT wires so they wouldn’t chafe against the cable. Although I can’t take full credit for the idea, the standoffs were quick, easy and cheap…and totally functional. I’m glad I still have a few of the real ones left for a couple of spots in the cockpit, but these work just fine for what I need.
I then reattached the “eyeball” firewall pass through fittings for the throttle, prop & mixture—which required some slight modification due to the fact that I had forgotten to run the cables through the brackets prior to final installation. Then I finished up the session by closing off the Safe Air wire bundle fittings on each side. I will probably go back with some RTV and seal a few spots, but otherwise the firewall area is done.
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Alternate air cable installed and functional
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SafeAir firewall pass through fittings completed
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My nifty wire standoffs
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