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Steves S-20 Build Site.
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Date: 10-1-2018
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Number of Hours: 5.00
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Manual Reference:
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Brief Description: Headsets and Plastic Parts.
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I spent most of my shop time this weekend hooking up the wires for the headsets. I am using only 6 pin lemo style connectors, and am not including the traditional phone plug style jacks. This presents a small challenge since the Dynon diagrams show the phono jack system, and no information is provided for the lemo connectors.
I ran into a couple of issues. First, I have some noise in the system when my panel mounted ipod is charging. I have read about cheap USB power ports causing noise, so I ordered a set of new power ports from Stein Air, who claim theirs are noiseless.
Then, I found that my Zulu PFX headsets had a very low "fluttering" sound that seemed to depend on where I was looking - Right ear if I looked right, left ear if I looked left, etc. The Lightspeed website says this can happen if the ear cups are not fitting correctly and they give some tips which I will try next time I am in the shop.
Next I plugged in my Clarity Aloft headsets, and one of them squealed, while the other seemed better. I had purchased adapter harnesses to fit with my Lemo connectors, and when I took a close look at them I found that they were not identical. An email to Clarity aloft was met with a response within 10 minutes to send the headsets in so they can get them working correctly.
Then I started on some of the plastic parts. I started with the flap lever cover. I found that tracing the very faint cut lines with a fine felt tip pen made cutting them easy. Then I taped a sheet of sand paper to my bench and used it to get the seam flat. I used a heat gun to mold the coneector strip to shape, and used the PVC glue from my local plumbing shop to glue it in place. The final task before painting will be to install the screws.
I also trimmed the closeouts for the elevator pushrods. The only thing I would note here is to watch the clearance as I needed to trim them a little more than I originally thought.
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Connector strip molded to shape with heat gun.
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Flap lever cover test fit.
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Elevator pushrod closeouts ready for paint.
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