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Kurt Haller RV-9A
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Date:  12-31-2017
Number of Hours:  8.50
Manual Reference:  
Brief Description:  Ailerons rigged, and other stuff

After the wing bolts were done, focused on finalizing electrical and p-noo-matic connections from the wings to fuse.

--Landing/Taxi lights: Used PIDG butt splices inside the fuse. Left about a 10' service loop, rolled up and secured to the wire bundles coming out of the spar carry-thru and the fuse side exit. Turned on the panel and tested--huzzah, we have wigging and wagging!

--Fuel qty senders: Image 1 shows the right side sender wiring coming over the spar. It turns out the BNC connector for the sender (a capacitance to voltage coverter) is right below a nutplate for the wing root fairing, hence one can't use a 1/2" screw. Max length is probably 3/8 rather than 5/16". In any case I'll probably have to cut down 1/2' screws, so I'll re-placard after determining actual max length. The wires were later put into split plastic conduit on the fore and aft side of the spar. (No conduit where the wires are sandwiched between layers of silicone self-fusing tape.

--Pitot and AOI: two 1/4" plastic tunes just barely fit in the grommeted pass thru directly below the aileron pushrod, along with the nav/strobe cable, taxi light wire, and fuel sender wires. I had another thick 14 ga wire to bring in from the wing--reserved for pitot heat when and if I ever get a heated pitot. So at first I had the pitot and AOI tubes come in on the bottom of the opening for the pushrod. They were put inside corrugated split plastic conduct and tie wrapped securely inside and outside. Turns out this left zero clearance for the aileron pushrod. *FAIL* *DO-OVER* I wound up bring the pitot tube in the grommeted hole with the rest of the wires, leaving just the AOI (in a small dia conduit) coming in over the edge. Plenty of clearance, good to go.

--Aileron rig: See images 2 and 3. Attached the aileron alignment tool to one wingtip, move the aileron to neutral. Now remove the tool and walk it over to the other wingtip and install it WITHOUT MOVING THE AILERONS. Methinks the rig art righteous.
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Fuel sender detail

Fuel sender detail

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Rigging righteousness: When the left aileron is neutral...

Rigging righteousness: When the left aileron is neutral...

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...so is the right.

...so is the right.

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