Smoke in the cabin! [19.0 hours]

Not really. But it poses a question in a 2 battery + 2 alternator electrical system. What do you do? There is only really one action plausible, which is “Both Masters OFF”.

When I did the Avionics, I figured I didn’t need a backup battery, because I had something better – a complete second battery/alternator system. That’s like a backup battery, but better … it can basically last forever. As an upside, it removes the weight and wiring associated with the backup battery. It was only when I went to do the complete wiring schematics that I asked myself the above question, and in so doing I realized that I did, in fact, need a backup battery. How else can I run a set of minimal Avionics after a “smoke in the cabin” event requires me to turn both electrical systems off. I couldn’t write an emergency procedure that said something like “turn one system off, wait a while to see if the smoke clears, turn the other off if it makes no change”, that would be silly.

So, I have to include the backup battery, to run a minimal set of Avionics in an emergency. However, there are many conditions where I would prefer to use the right electrical system as the backup, since it is far more capable. If the left electrical system went down for any reason, the right electrical system should be used as the backup. I didn’t want to start adding switches to manually select these choices, because:

  • In any emergency situation, a pilot will tend to suffer a large drop in IQ. Adding switches and actions to deal with the emergency situation is just asking for trouble.
  • Any sort of manual changeover could bring about a situation where the Avionics power went off, then back on, requiring the EFIS’s to reboot. This takes time – the last thing you need when an emergency occurs.

Therefore, what I need is some kind of automatic changeover. If the right electrical supply is present, then it should be selected as the backup source. If the right electrical supply is absent, then the battery should be selected as the backup source. Power diodes? No thanks, don’t like them. A non-latching relay would work, but then I’d need a switch or something in order to test the battery on startup. It’s starting to get a bit complex. There’s also circuit protection, and the need for a charging path to charge the battery. What I really want is a system that does the automatic changeover, with no energy loss when operating off the battery (no diodes, no relay coil current), and that yields good visibility to the condition of the battery, charging state etc. With this in mind, I designed a small board to manage the backup battery requirements.

The schematic for the board can be viewed here.

Over on the right, a latching relay is used to switch “Backup Power” between the right battery/alternator system and the backup battery. The FAN3240 and associated components drive this relay. In the center left, a small Arduino board controls everything. This needs a tiny amount of 5 volt power, whenever either the battery or right system is present. Up on the top left, protected by polyfuses, these two power sources are diode OR’d to provide 12V for relay power and a small linear regulator provides 5V for the Arduino board. On the bottom left, a level translator provides an RS232 serial port for remote monitoring. Finally, the “headset power” for Bose etc. headsets is tapped off a convenient point that has power if either the battery or right system is alive. In an emergency, the (trivial) power for ANL headsets will still be provided by the TCW battery – this isn’t a bad idea, in an emergency with minimal avionics, we would be better off hearing any VHF traffic clearly, right?

The Arduino controller has scaled analog inputs to sense battery voltage and right supply voltage, as well as the sense and “low voltage” outputs of the TCW IBBS. Two outputs from the controller are used to set or reset the latching relay. The code is trivial and simply selects the right system in preference to the battery, if it is present. A remote communications protocol allows a host system to determine the status at any given time, including measured voltages and the direct IBBS outputs, and to force the system one way or another for testing.

A modified backup battery harness is required to use this system with the AFS ACM. Page 155 of the ACM manual (v6.5) shows the standard harness from the TCW IBBS backup battery to the AFS control module. Here is a link to the actual harness I made to accommodate the new battery backup board.

I mounted the TCW IBBS on the back of the sub-panel, behind the AFS ACM. That makes it a bit hard to get to, unfortunately, but I didn’t have much choice by this point because all of the front sub-panel space was used up. The battery backup board is mounted near the ACM, I didn’t bother putting it in a case, there’s no reason to do so. Here’s a not-very-good picture of the first, hand assembled, prototype sitting in position on the sub-panel, ready for test. There’s one panel switch – the standard low-power one required by the TCW IBBS to enable the backup battery. Apart from this, everything else including test is handled remotely and can be viewed/controlled if need be from the small TFT display I’m using on the front panel for annunciation and monitoring of the EFI redundant power system.

Prototype battery backup controller

Power system for SDSEFI

Background

Some time ago I decided to use the SDSEFI system for the IO-540 engine in this aircraft. This article is not about that decision, but rather the various implications of having an electrically dependent engine and how I am dealing with them.

Disclaimers:

  • No representation or warranty as to the suitability of anything described here is given, for any purpose.
  • Nothing described here is endorsed by any manufacturer, in particular SDS/Racetech.

SDSEFI Component Redundancy

There are various physically separate, redundant systems involved in the SDSEFI system:

  1. Two separate ECU’s, with mostly independent/duplicate sensors
  2. Two separate Hall sensors
  3. Two separate ignition systems, with two spark plugs per cylinder

Power system redundancy

There are all sorts of debates, which can be viewed on VAF and elsewhere, about the “best” way to deploy a single engine aircraft electrical scheme for electrically dependent systems. I won’t fill a post repeating all this material. The bottom line for me, after a few too many decades in semiconductor, hardware and software engineering, is this:

  1. True redundancy means having two physically independent systems
  2. Physically independent means these two systems do not come anywhere near each other. This includes wiring and conduit runs.
  3. Anywhere that physical independence is not possible, circuit protection must be employed to ensure that no single point of failure can bring down both independent systems.
  4. The aircraft must stay fully available for IFR operations, for as long as fuel is available, in the event either one of these physically independent electrical systems goes down.

(3) above comes about because there is only one fuel injector per cylinder, unlike everything else with the SDSEFI system there are no redundant injectors.

(4) above comes about because Australia is a big country, with large regions that contain nothing. Hitting “Nearest” on the GPS would rarely provide the kind of options that the same button does in the USA.

Implications

The only system that complies with the above requirements is a 2 battery + 2 alternator system. A dual SDSEFI system for an IO-540 typically draws 14 +/- Amps, so relying on a Battery alone with no alternator would not yield much flying time, given this load plus a minimal set of essential avionics. While a single battery / dual alternator arrangement is a fine implementation for many situations, it doesn’t really fit the bill for me.

Given two physically independent electrical systems, the question becomes how to arrange for reliable injector power. The classic “essential bus” arrangement with large power diodes doesn’t really fit my mindset, the “essential bus” itself is, as far as I’m concerned, a single point of failure for the entire system. The dominant failure mode for power diodes is to fail as a short. This may well go unnoticed – until it matters – or it may lead to a cascade of other failures that compromise both power systems.

My primary goal is to provide the required power redundancy for the injectors, and electrically dependent engine systems as necessary, but in a manner that distributes circuit protection such that no single failure can bring the system down. This activity led me down a very long path, encompassing the entire electronic, electrical and electro-mechanical aspects of providing and monitoring power for the SDSEFI based system. After several discarded prototypes, I’ve settled on the system and am describing it in this post.

A secondary goal is to simplify the startup procedure, while enforcing the necessary checklist actions, for engine start and ground checking the various redundant SDSEFI systems. This issue has been discussed in a VAF thread, I wanted to avoid having a bewildering array of switches. I do not, however, subscribe to the school of thought that any pilot should be able to jump into the aircraft I’m building and take off, as far as I’m concerned transition training is required for any new aircraft and that encompasses the entire set of aircraft systems. It’s inconceivable to me that this training would not include a comprehensive understanding of the SDSEFI system, and associated electrical system.

A further secondary goal is to allow monitoring the various injector, ignition and fuel systems, to the extent that the use of electronic circuit protection allows such observation. We’re all used to having advanced engine monitors as part of EFIS based avionics these days, but current day monitoring systems do not cater for monitoring the components that make up the SDSEFI system – electrical fuel injectors, coil packs and fuel pumps. There’s a wealth of information hidden in these systems, and the goal is to expose it in a manner that (i) does not distract the pilot, but (ii) allows in-flight observation/confirmation of a failure and (iii) allows early observation and/or notification of a component which may be on its way to failing, before an in-flight failure occurs.

About complexity…

A likely comment about the following description is that it is all too complex. That is a fair criticism, the system I’ve built is certainly not for everyone. Of course, the insides of just about every one of these magic electronic aviation boxes in common use today is complex, but much of that complexity is hidden from the user. I can’t think of many projects across my own years of design experience that were not internally complex, even for products that on the outside appeared relatively simple.

System Overview

There are three main components associated with the redundant power system. These are:

  • A redundant power board, mounted behind the panel, that contains electronic circuit protection and redundancy for the fuel injectors, electronic circuit protection for the coilpacks and fuel pumps, and monitoring of all circuits. The power board contains completely autonomous hardware for redundancy and circuit protection.
  • A small TFT touch display, mounted on the panel, that allows monitoring and control of the power system
  • An embedded CPU, mounted under the pilot’s seat, that communicates with both the power board and the display. The CPU handles many items that are essential for ground runups, but there is no in-flight requirement for either the CPU or the associated touch display, these items can fail and have no impact on safety or continuation of an IFR flight.

I’m not going to describe the CPU or touch display here, instead this post will focus exclusively on the power board.

Redundant Power Board

This is the key component for power redundancy to the injectors. I’ve burned through a lot of time and several prototype cycles evaluating various technologies and arrangements before settling on the final configuration. Over April I hand built a full prototype board, and tested it against my engine emulator (more on that later). Based on this testing and some final modifications, I’ve this week released a new board design and, for the first time, I’m getting these prototype PCB blanks produced as they would be for a production run, rather than in a cheap version used purely for prototypes. I’ll hand stuff one of these samples when the blanks arrive in a few weeks time, and repeat/continue testing. Eventually, of course, I’ll have to do a small production run at a board assembly facility in order to ensure adequate build quality for use in the air. I would never fly on a hand assembled prototype!

Here’s a picture of the most recent prototype:

March 2021 redundant power board prototype

This is the afore-mentioned place where the two separate power systems – unfortunately – have to come “near each other” so that, in the event one of the electrical systems goes down, power will still be applied to the injectors from the other bus. Rather than having a single “essential bus” using large power diodes, this board handles redundancy for the injectors in a distributed manner, with each injector power system isolated and protected from the other injectors.

Here is a link to the schematics for the current revision of this board. These schematics come with no warranty as to correctness or suitability for any application whatsoever.

Per-injector supplies

There are 6 identical redundant/isolated supplies, one per injector. Sheet 2 of the schematics contains the supply for injector 0 (cylinder #1). For the injector supplies, I’m using TPS1HB35 devices for circuit protection and current monitoring. These are rugged devices with internal over-current and over-temperature protection, low ON resistance and a sense output for monitoring current, junction temperature and fault conditions. Current limit is set to 5 Amps, and the device may be set up to either retry about every 2 msec in the event of a fault condition, or latch the fault condition (if the latch input is high), requiring external intervention. This device operates from the primary (left) bus, corresponding to the main alternator. A fuse (or PTC) on the left side of the schematic protects the left supply from board level failures at this point, it will not blow in the event of an injector wiring failure – the TPS1HB35’s protections will kick in first.

On the right side of the schematic, providing redundant switchover in the event of a failure of the primary supply, is an old fashioned electro-mechanical relay. In the open “unpowered” position, the injector supply will come from the secondary (right) bus, via a protective fuse. I entertained all sorts of electronic arrangements for providing this redundancy, but ultimately decided on the complete isolation this scheme gives. These are hermetically sealed relays with contacts that are rated at 5 Amps continuous current. The relay is non-latching, with a coil current of only 11.4 mA, with a functional vibration resistance of 20G. Since the relay is non-latching, if the left supply fails for any reason, the relay will be un-powered and go to the open state, switching the injector to the secondary (right) supply.

The sense output is set up to track output current, 1 volt of sense output per amp of output current. There is a micro-controller on the board which runs a bunch of ADC’s sampling sense currents from each injector, with firmware that looks for pulses. The board contains both USB-C and RS232 connectors, allowing remote systems to ask for and receive more-or-less real time data from the current sensing, and here is an actual screenshot from the little TFT display for the injector waveforms derived from a live test running six pulsed fuel injectors powered from the prototype board:

The little “blip” on the rising edge of the waveforms corresponds to the opening of the injector pintle, as it causes a back-emf that results in a momentary reversal of the injector current. The TPS1HB35’s have low on-resistance and run cool, with measured junction temperatures only a few degrees above ambient. Shorting an injector is a non-event, with the associated TPS1HB35 going into fault mode. In “automatic” fault mode, retrying about every 2 msec, the TPS1HB35 junction temperature rises by just a few more degrees.

There’s obviously a lot that can be done with the software/display systems to highlight faults or unusual behaviors, as well as the firmware, there’s ample room to do signature or other analysis, an FFT on the pulse etc., but for the time being the main point is to exercise the redundant power system hardware/firmware and test it under real world conditions. I have a lot of data, not presented here, which has made me comfortable with the design and performance.

Coilpacks and Fuelpumps

Originally, I prototyped the power board for injectors only. I thought about doing a separate board/box, for a coilpack/fuelpump pair, so there would be one for the primary/left and one for the secondary/right systems. The aircraft wiring associated with such an arrangement started to take on a life of its own, the more wire segments and connections in a system, the more prone to failure it is. A few years ago I worked on a hashing chip design that had core power requirements of 1.2 Volts at 600 Amps. The package exposed bare die, with a water cooler clamped directly to the silicon. The board power supply design to support this amount of current was a wild ride, but eventually worked out just fine in 3oz copper.

I did some calculations and decided that with 2oz copper I could easily support the required currents for the coilpacks and fuel pump circuits, even under short-circuit conditions, and that a single board to support all devices would minimize the amount of electrical wiring while still being able to maintain complete isolation between the left and right supplies. As a bonus, the same micro-controller could be used to sense coilpack and fuelpump currents, requiring just a single communication connection to the host CPU system.

Sheet 10 (thru 13) of the schematics show the circuit protection arrangement for the coilpacks and fuel pumps. These are dedicated electronic protection circuits for each of the four devices, two each on the respective left and right supplies. There is no notion of electrical “redundancy” since the devices are physically redundant themselves.

Here I use a higher current device in the same family, a TPS1HB08B high side switch. Trip current is around 19 Amps, which sounds like a lot but has to be high enough to allow for (a) the rate-of-change of current for the coilpack circuits, since the TPS1HB08B protection looks at rate-of-change as well as absolute level, and (b) the turn on inrush current for the fuel pumps, which I measured at 13 Amps for the sample pump I’ve used for testing. There is no separate fuse, apart from the master 30A fuse next to each battery, the TPS1HB08B is the fuse. The “left” and “right” coilpack/fuelpump pairs are physically separated on the board, by quite a large distance.

There is a “disable” input for each device, primarily to allow coilpacks to be disabled during ground runup checks. Again, sense outputs allow real time output current measurements to be made, and faults to be detected. The microcontroller firmware again looks for pulses for the coilpack circuits, or samples continuously for the fuelpump circuits. Here’s a TFT display screenshot, from real time data collection, with an identical coilpack to that used for SDSEFI driven by a pulse system, with spark plug loads. The fuel pump in this case was a purely resistive load:

In this case the coilpack dwell time was too long, the current limiting that is occurring was protection from the coilpack drivers I used. A more reasonable dwell time would result in a simple triangular waveform. To test the fuelpump circuit, I bought a cheap Ch*nese fuel pump from EBay for next to nothing. The fuelpump current is sampled continuously and the resulting waveform represents commutator action. I placed this fuel pump in a bucket of water, recirculating the outlet, and within a few days the thing showed clear commutator degradation. This was an excellent test of the sampling and display system, here is a screenshot:

I was wondering how to find a broken fuel pump to test how the small display system could show degrading performance, but it turns out all I had to do was buy a cheap pump on EBay and make it pump water. Here’s the same waveform on the scope, as measured directly from the board’s sense line. A more reasonable pump would have a fairly constant commutator ripple rather than the one shown here:

Seeing this poor knockoff pump struggle within days of first operation has made me feel better about the time I’ve spent going to the trouble of allowing the design to monitor and sample data from these circuit redundancy/protection systems. A fuel pump showing the above behavior may well pump adequately to maintain fuel pressure, but it is clearly on the way out and it would be far better to know about this and replace the pump on the ground, rather than wait for an unexpected in-flight failure.

Coilpack and Fuelpump circuit operating and fault conditions

These coilpack and fuelpump circuits have necessarily quite high fault current settings. We’re normally blind to this, where (say) a 15 Amp slow-blow fuse would provide the necessary protection and the impact of a failure event, as brutal as it may be on the electrical system, is limited to the time it takes the fuse to blow. Even under normal operating conditions, these circuits are far from pure. Consider for example the coilpacks.

Coilpack dwell time is nominally around 3.5 msec in the SDSEFI system, during this time the coilpack current will rise fairly linearly from zero to up to around 7 Amps, and then rapidly drop back to zero. In the RV-10, with batteries behind the baggage bulkhead, there is several meters of wire supplying power to the coilpacks. The resistance of this wire, together with the effective internal resistance of the battery/alternator system, causes a measurable drop in the supply line at the redundant power board. Here is a measurement, the trace shows the approx. 14.4 Volt supply rail dipping by around 0.25 volts during the 3.5 msec coil dwell time, followed by an approx 1.5 Volt inductive spike when the load collapses. Equivalent engine RPM is 2700, so these are frequent, ongoing events:

In the case of a coilpack/fuelpump device or wiring short circuit, the TPS will either turn off and latch the fault condition, or keep retrying around every 2 msec if the “latch” input is low. Retrying under short circuit conditions, with the high fault current setting required for these devices, is a safe but nonetheless violent condition. Here is an example where the TPS turns on the output after a fault, detects the circuit still in fault, and turns off again. The purple trace is the 14.4V supply rail, which can be seen to dip by around 2 volts as the short-circuit current ramps up across around 20 microseconds, before bouncing back after the TPS re-enters fault mode and turns the output off again. Under continuous fault retry conditions, I measured a junction temperature rise of 60 degrees C above ambient for the corresponding device. The system took it OK, even when hit with a heat gun to raise the ambient temperature further, but it’s probably not a situation I would allow to continue indefinitely.

Since I have firmware control over the state of the “latch” input to each TPS individually, I can decide down the road a bit whether to allow the automatic retry thing to go on or whether, for these circuits, to latch the fault and allow some sort of an in-flight option (through the TFT display) to retry the circuit. Think of it as a normal circuit breaker, but controlled through the touch display. Given that there are two physically separate coilpacks and two fuelpumps, there is a good argument for simply latching a fault and not distracting the pilot by trying to do anything about it in-flight. The main point at present is to nail down the power board flexibility I need to build in so I can change these sort of behaviors at a future date purely through firmware/software changes.

While on these sorts of pictures, here is a fuel pump turn-on event, showing a rapid starting current rise to about 13 Amps, settling down to the operating current of around 4 Amps after 75 milliseconds:

Micro-controller

Sheet 7 of the schematics shows the micro-controller circuitry. This is a conventional STM32 based system, with both RS232 and USB external interfaces. There are five ADC’s in the STM32G4, these sample 10 analog inputs corresponding to the six injectors, two coilpacks and two fuel pumps. These ADC’s sample continuously, with 4X oversampling and a total conversion time of 4.82 usec that alternates between the two inputs. Across a coilpack dwell time of 3.5 msec, this gives 300 samples which is more than enough to yield a good representation of the waveform. DMA controllers map ADC output directly to main memory, and as mentioned previously firmware goes hunting through the blocks of ADC data looking for pulses, which are then normalized and centered in buffers ready for acquisition by an external host through a communications port.

There is no dependence on the micro-controller for in-flight operations. If the micro-controller fails in any way, it cannot effect circuit protection or the integrity of the redundant systems. There are some unusual things on the right hand side of this sheet to ensure this. The “disable” signals used for checklist items during ground runups do cause real actions with the circuit protection devices, and if these were permanently wired to the micro-controller outputs, then a micro-controller or board failure which drove these signals could potentially turn off a power circuit. To ensure this cannot happen in-flight, a set of relays disconnect these “disable” signals from their respective destinations. The relays themselves can only be energized by a charge pump circuit, that will only turn the relays on when a micro-controller output is pulsed at a rate of around 5 KHz. A failure of this output, to either high or low or open, cannot close the relays, thereby protecting the system from faults in the micro-controller section.

Engine load emulator

To debug and test this system, I needed a load emulator that looked the same as the engine does. For this, I bought a coilpack, six plugs, harness, six cheap high impedence fuel injectors etc., all from EBay, and mounted them on an Alclad plate (in fact the standard VAN’s RV-10 panel which I had no further need for). I did a board with FET’s and coil drivers, and used an STM32 evaluation board I had on hand to drive it all. This allowed me to drive injectors and coilpacks with pulses, controlled remotely via a USB connection to a host based testing system. As noted earlier, I also have a fuel pump in a water tub. I have resistive loads that I can switch over to for the injectors and the fuel pump, because it’s hard to think while a bunch of fuel injectors are clacking away, they make a surprisingly annoying sound. Here is a short video of the load system in operation, with all injectors and coilpack points in operation (there’s foil around the spark plugs because the EMI was crashing a nearby open computer):

It’s really aggravating in operation, which is why I can switch things over to resistive loads for certain testing. I don’t think the fuel injectors will live for long with no fuel flow for cooling, and I made a bit of a mess of the load board design so some things recently blew up. The load system has proven to be very useful though, so I’m going to spin a better load board design, install a second coilpack etc. so I can more closely emulate the complete IO-540 engine configuration. I’ll use this for first bringup of the system once installed in the aircraft, by hanging wires through the passenger side door and in behind the panel.

I need to do a lot more testing with the next prototype board, and with manufactured boards. Thermal testing with the power board in operation inside an oven at elevated temperature, etc. so the engine emulator will see a lot of service before first start of the real engine.

Redundant power board physical considerations

Obviously with both the right and left coilpack/fuelpump systems, and the entire fuel injector power system, on the redundant power board it is a critical part of the aircraft electrical system. To this end, there are various design considerations that have gone into how connections are made, and the physical / mounting aspects of the board. Here in no particular order are some of these considerations.

  • It is only a 2 layer board. There are no internal layers. There is no doubt that, with a couple of internal layers, the board could be quieter, and the ADC measurement points could be routed in a much nicer/controlled manner. However, I didn’t want the added complexity of a 4 layer board, or any power plane other than a bottom ground plane.
  • The board is 2 mm thick, which is a bit thicker and more resilient than a regular PCB. I may make it thicker still.
  • Copper weight is 2oz, which gives plenty of margin for the higher current traces
  • Power and ground connections to the board are all made with M4 screw terminals. I didn’t want to use anything other than ring terminals for these critical connections. There are two ground terminals – left and right – which go to their respective ground bolts on the firewall.
  • Injector, Coilpack and Fuelpump power connections to the board use high reliability Harwin M80 connectors. These connectors have screw/nut retainers both to the board and between connectors. They’re expensive but this is a critical application, which warrants the extra expense.
  • Not noted above is that power for the ECU’s, and for the injector relay box, comes from additional pins on the Harwin connectors used for the left/right coilpack+fuelpump harnesses. On board circuit protection for the ECU’s is included for these outputs, further reducing the need for extra aircraft wiring for these points.
  • The power output connection for the SDS injector relay changeover box is active if either left or right power busses are available. I note that later versions of the SDS injector relay changeover box have two power inputs, but mine has only one.

About checklists

As noted earlier, checklists are imperative for so-called “advanced” aircraft systems. Some aspects of the redundant power system design, such as the ability to disable supplies, were done to aid in ground checklist items that would normally require switches, but that could be done electronically given the capabilities of the touch display and the redundant power board. Without further explanation, here is a copy of a worksheet I’ve used to confirm the required capabilities are present, this data will eventually contribute to the relevant printed checklists for the aircraft. Thanks go to a spreadsheet generously shared by another RV builder, John B., who provided the basis for this layout.

Maintenance

There won’t be much in the way of maintenance requirements for the board, apart from the usual annual checks of the wiring connections. I’ll have spares on hand since I will have to do a small manufacturing run, and the board doesn’t really weigh anything so there’s no reason I couldn’t carry one as part of the aircraft spares kit on a longer cross country journey. For the on-board fuses, I considered replaceable fuses in small cartridge carriers, but discounted this, since they add mechanical connections and associated reliability concerns. I considered PTC’s as well, and have the option in various cases to decide which at a later time since the footprint is the same, but by and large I prefer the rugged reliability of surface mount fuses, and if one blows there will be an external reason which has to be addressed anyway.

Conclusion

If you want to build quickly and get your RV-10 in the air as soon as possible, use magnetos and mechanical fuel injection. Proven, reliable technology.

If you decide to use electronic ignition, or ignition and fuel injection, so that you have an electrically dependent engine, then you need to think through the mission parameters and design a robust electrical system that will satisfy the mission requirements. This can often lead to a significant commitment in time and resources. I hate to think of the time I’ve invested so far, as a result I’ve decided to log zero hours for this activity.

Bone pile of EFI power board designs that didn’t make it

Inlet plenum success! [1.0 hours]

It took some time to get back to my “Showplanes Cowl with A/C left hand inlet plenum problem”, but this week I finally unleashed my new 3D printer on the problem, and the result was great.

This is a complex part, and I evaluated several different slicing applications to figure out how to do the necessary support structures. I wound up using Cura, because of its “Tree” support capabilities. It generates all sorts of weird tree trunk/branch constructs to support the part while it is being printed. This results in less interference between the support and the part.

It took 4 days 16 hours to print the part in ASA, using a bed temperature of 100 deg C and a 0.4mm nozzle at 250 deg C. I did gear up to use a dissolve-able filament (HIPS) between the support and the part, but decided for the first trial to simply use the one extruder. As it turned out, the support was easy to rip away with a pair of pliers, so I’ll stick with the single material process to save time and complexity.

There were a few areas where the support came slightly adrift, causing rough regions on the part. I need to fix this by manipulating the support to have better adhesion to the bed. It takes about 5 hours to render the model, another hour or so to “repair” the STL, and about an hour to slice the result and generate gcode for the printer. Although the part as printed is certainly usable, there are areas I can improve on. Since each printed part is a 5 day exercise from start to finish, and comes with a filament cost, I won’t be spinning revisions too often.

There are some new materials around, Polyamide with Carbon Fiber filler, which are stronger and have higher operating temperatures, up to 180 degrees C. I can print these materials if I install a hardened nozzle on the printer, but I’ll hold off on this until late in the build because the filament is expensive, and there are new products hitting the market all the time.

For now, I have the entire process under my own control and I’ve been able to print a perfectly acceptable part – mission accomplished for the inlet plenum, finally. Now I can finish the front baffles in this area.

How many hours have I spent on this? A lot, between assembling the printer from parts, calibration, printing test parts, evaluating slicer software and monitoring the printing of the plenum. None of this is really direct work on the air frame, so I’m going to simply log 1 hour for this activity, knowing full well that it was many times this.

  • f58a
    f58a
    Starting the inlet plenum print, layer 1
  • f58b
    f58b
    A day in, and a long way to go
  • f58c
    f58c
    A bit over half way
  • f58d
    f58d
    Nearing the end
  • f58e
    f58e
    Print complete!
  • f58f
    f58f
    Support rips away quite easily
  • f58g
    f58g
    Complete part less support
  • f58h
    f58h
    Installed - and a perfect fit!
  • f58i
    f58i
    2 inch connection is for heat muff SCAT tube
  • f58j
    f58j
    Room for A/C connections
  • f58k
    f58k
    A/C line connections will work OK
  • f58l
    f58l
    Air filter fits inside here, fits into standard Showplanes system
  • f58m
    f58m
    Clearance around A/C compressor
  • f58n
    f58n
    Side view

Where did winter 2020 go? [100.0 hours]

I got an E-mail from someone wondering why I stopped posting.

I’ve been steadily working the project, but having reached the “90% done, 90% to go” stage, it’s been hard to progress many tasks through to completion. Winter down in Tassie was long and cold as usual, and the short days tend to slow down workshop hours. Thankfully that’s now behind me for the year.

The inlet plenum 3D printing work reached a stalemate. After many Covid delays, I received the second prototype and it was damaged in transit due to poor packing. I worked with the vendor and insurance to have it replaced, and after yet more Covid delays the replacement arrived, also smashed in shipment. I was able to tape together enough pieces from the two parts to decide that the shape was going to be correct; however, I lost faith in the high temperature epoxy material – it was clearly too brittle. The correct material is ASA, but the quality of the first prototype was not good enough. In order to compete in online 3D printing services you need the lowest price, and there’s a big difference between how this first prototype was printed and how I would want it done. I talked to a few vendors in Australia, and it was clear that the cost would rapidly escalate into the thousands of dollars, for each printing, and I might want to do more adjustments yet. I decided to shelve the work, and ordered a commercial grade large form 3D printer. After months of delays, some again due to Covid-19, this thing will arrive here next week. The only problem is it arrives in 8 boxes and I have to assemble it. Once I get it up and running, I’ll be able to print the plenum as many times as I care to, with the quality I want, before calling it right.

I designed all the overhead panels, some auxiliary panels for headset connections etc, and settled on the replacement lower panel arrangement for the Aerosport 310, which was previously incorrect. I worked with AFS to get these designs finalized and the panels are being cut and printed at this time. In the meantime, I made some cardboard replicas and used these to do most of the overhead wiring. I’m not willing to post a photo of that.

I’ve been doing the wiring, which is a big job for an RV-10 made bigger by my choice of 2 batteries, 2 alternators, a 3 screen panel, A/C and SDS EFI. The wiring is about half done overall, and currently looks like a disaster. I started out wanting to simply do the wiring behind the baggage bulkhead and through the overhead, so that I could finish up the tail and put the final skin on. This plan rapidly devolved into an acceptance that I had to do all of the wiring, there are too many interactions to lock up one part before all parts of the puzzle are solved.

Associated with the wiring are some custom electronics. These pieces are:

  • Backup EFIS power. The backup EFIS power nominally comes from the second battery/alternator supply. However, what is the action in the case of an electrical fire and smoke starting to fill the cabin? It has to be “both masters off”, there’s no time to figure out which system is the problem. The engine will keep running because the EFI system is separately powered, but in order to keep minimal EFIS functionality, the regular backup battery must be used. So, I designed a board which will supply backup power to the AFS system, which will come from the secondary battery/alternator system if it is running, otherwise will come from a backup battery. Changeover is automatic, and the functions are ground tested as part of the runups.
  • SDS EFI power. Although the ignition systems, the two fuel pumps and the two ECU’s are on physically redundant battery+alternator systems, there is only one set of injectors so I needed what some would call an “essential bus” to run the fuel injectors. Any place physically redundant systems have to come together is a problem so I’ve applied some effort to this which I’ll post more about in a few months time.
  • Monitoring and logging. Between the extra TFT display on the panel, the EFI power system, the battery backup system and the A/C there are various sensors and data monitoring that I wanted brought back to a central non-essential point. A small embedded computer system sits under the pilot’s seat and has various communication methods to collect data and present information on the extra TFT display. This may eventually be a last resort backup EFIS, but not initially. I needed a set of interfaces for this embedded system that went beyond what is commercially available, so I’ve done a board for that as well. The prototype worked OK with a couple of jumpers and I’m re-spinning the board now.

In between all these activities, I found I was missing various miscellaneous/low-cost parts, which I’ve procured on a slow track with a few consolidated shipments from the US, again affected somewhat by Covid delays.

Reading through all of the above, it’s clear that I’ve done quite a bit over the past few months, but haven’t managed to actually finish anything. When I finally do manage to finish something, I’ll put up a celebratory post that will include some photos.

I have no idea how many hours I’ve spent on the above over winter – quite a lot – but I’m just going to log 100 hours because I really haven’t kept track of it all.

A/C Evaporator

I bought my A/C kit quite a few years ago from Airflow-Systems. I was shipped a so-called “Australian” evaporator, which is actually a product called a Monster Trunk System, part #685000-VUY from https://www.vintageair.com. There was a collection of metal parts and adapters in the kit, with no obvious way to set up the air flow and no instructions for this evaporator unit. The evaporator contains a 3 speed high volume scroll blower, which is ill suited to pressurizing the overhead console. Several other builders have supplemented this evaporator with an inline blower  which is more capable of pressurizing the overhead console. Yet another technique has been to forget about the overhead, turn the unit around and fit enough ducting to blow air straight into the cabin – see here.

I was already committed to a conventional mounting position, having done the inlet ducts and cutout for the overhead several years ago. What I needed to do was complete the evaporator outlet ducting, including an inline blower to suitably pressurize the overhead console, cabin flood air ducting, and a means to use the rear NACA vent air, via the Aerosport products NACA vent valve. This exercise is complicated by the fact that there isn’t a single right angle anywhere in the system, and it all rapidly turned into a 3D modelling exercise. First though, here’s a description of the evaporator inlet system I put together a few years ago:

The F-1006 bulkhead attachment for air to pressurize the overhead is a difficult area. In order to get enough air volume, a significant cutout is required. This mandates a doubler plate, and there is not much room to fit one. Edge distances, strength, clearances, Aerosport overhead console flange dimensions and screw positions for the rear baggage bulkhead all come into play. I wound up using both a shim plate and a doubler, in order to tie the doubler in with the rivets which secure the top of the F-1028 baggage bulkhead channel. Rivets for the doubler are flush on the rear side (where the manufactured heads are inside the overhead console air space) and flush on the front side where the baggage bulkhead overlaps the F-1006 flanges. I lowered and moved the normal position of the baggage bulkhead top screws, in theory they should have landed right in the middle of the Aerosport overhead lower flanges, in practice they are a little above this point but still easy enough to install.

This whole area is so busy, it is difficult to find a good way to “attach” the required air duct(s) to the bulkhead. It’s also not reasonable to have hard attachment points between the bulkhead and the evaporator/shelf, due to vibration and cracking. The idea of this design is to use a 3D printed bulkhead attachment block to achieve the following:

  • It can be fitted to the F-1006 bulkhead after the top skin is riveted on, sealed with some form of gasket material, and brings the air duct attachment plane clear of the bulkhead.
  • Two long #6 screws act as locating pins for the flange of the main attach duct.
  • A thick/soft gasket or manifold can be used between the rear of this bulkhead attachment point and the main duct, to seal airflow and provide vibration isolation.
  • If (when) the evaporator arrangement changes, a new 3D duct can be printed to mate with the existing bulkhead attachment point.

I use only one hole for airflow into the overhead, the side with more area (the F-1028 is offset from the center). Manifolding air into both sides complicates things and is pointless – what matters for overhead air is pressure, not volume. I wanted electrical connections into the overhead as well, so these are on the right hand side of the bulkhead, and will be sealed off in the overhead.

  • f20a
    f20a
    Cutout for overhead air feed, with shim and doubler plates
  • f20b
    f20b
    Holes for electrical conduits into overhead, with doubler plate
  • f20c
    f20c
    3D printed template for bulkhead attach block, to verify it clears all obstacles.
  • f20d
    f20d
    3D printed ABS bulkhead attach block, bulkhead side.
  • f20e
    f20e
    Bulkhead attach block trial fit. Installation can only happen after top skin riveted on.
  • f20f
    f20f
    A/C evaporator on shelf, with 3D printed inlets.
  • f20g
    f20g
    3D printed inlets are contoured to match the curved front surfaces of the evaporator.
  • f54a
    f54a
    Production inlet parts, made from tough epoxy, to replace the ABS prototypes
  • f54b
    f54b
    Production inlet parts in place
  • f54c
    f54c
    Cutouts done, nutplates in place
  • f54d
    f54d
    I added a stiffener to the front face
  • f54e
    f54e
    Fitting a rubber seal over the original evaporator inlet
  • f54f
    f54f
    Cover plate in place, screwed on. Rubber pads on front of inlets, riveted on and sealant applied
  • f54g
    f54g
    Cutout in evaporator shelf for receiver/dryer
  • f54h
    f54h
    Clamping shroud for receiver/dryer

For the evaporator outlet, I designed a manifold which caters for the following requirements:

  • Fits onto the two irregular shaped outlets on the evaporator, with a simple rubber seal and some screws.
  • Provides an outlet for the inline blower. I used a 4″ blower, because it fits. A 3″ blower would probably also be adequate.
  • Provides a pair of outlets for cabin flood air. These should probably be 2.5 inches each, I used 2 inches because that’s the attachment size I have room for on the front (top) bulkhead.
  • Provides a pair of inlets for the Aerosport NACA vent valve, to feed vent air from outside into the system
  • Provides a place to mount a temperature probe
  • Can be assembled in-place, or if necessary by lowering the rear edge of the evaporator shelf (after removing the support).

The following pictures show what I came up with. I had the prototype fabricated in tough epoxy, and it fitted fine except for an indentation on the top that I made to clear the top stiffener. For some reason my measurements were off, and the indentation missed the stiffener by 20mm. I fixed this up and made some other improvements, and just ordered the final version which should arrive here in another week or so.

The 4″ blower just fits in the required space. I’m mounting it to a metal bracket that will be riveted to the cover plate I made up for the evaporator inlet. Also mounted on this cover plate are three relays (for the scroll fan) and a pwm controller for the inline blower. A wiring harness for this can be seen in the pictures, not properly laced up or secured yet. A high side pressure sensor, and evaporator air outlet temperature sensor, are included. The system controls will be on the overhead, except for the master “A/C on” switch which is on the front panel, pilot’s side. Turning the A/C off (before rolling) will be on the pre takeoff checklist, if necessary it can be re-engaged at some point during climb out. Part of the wiring includes a connector that could be used for a micro-controller that would be capable of climate control, if the rotary switch in the overhead is set to the “auto” position.

The final duct is to go from the outlet of the axial blower to the overhead. I printed some prototypes for this on my own consumer grade 3D printer using a flexible material. Once the shape was correct, I decided to order the production part in SLS Nylon. This will be very strong, but will still have enough flex to effectively detach the evaporator/blower assembly from the airframe. Although I will be assembling all of the final components with the top skin still partly open, everything is designed to be removable and reassemble-able after the skin is in place. It won’t necessarily be pleasant working back there in the hell hole, but it can be done. For assembly, I’m going to take advantage of the skin being off and will cheat as follows:

  • With everything in the tailcone finished, and with the evaporator/shelf removed, cleco the top skin on in its entirety. With Rosie outside on the rivet gun, and me inside, we’ll rivet the holes across the front and towards the rear on each of the three stiffeners.
  • Remove all the remaining clecos, allowing access from each side.
  • Fit the bulkhead adapter and the (flexible) duct from the inline blower outlet to the bulkhead. This can’t be done until after the (above) rivets are set.
  • Install the evaporator, shelf, outlet manifold, inline blower, NACA vent valve etc, using the access from each side to make the job easier this first time.
  • Fit the remaining refrigerant hoses etc. and charge the system. I plan to use an electric motor with a grooved pulley and a long serpentine belt as a means to run the compressor for this step.
  • Check for leaks and proper operation.
  • Cleco the skin back up, climb inside and finish riveting on the skin.
  • evap_out-1
    evap_out-1
    Evaporator outlet manifold
  • evap_out-2
    evap_out-2
    Top view
  • evap_out-3
    evap_out-3
    Bottom view
  • evap_out-4
    evap_out-4
    Right side view
  • evap_out-5
    evap_out-5
    Left side view, small hole is for temperature sensor
  • evap_out-6
    evap_out-6
    Front pump, vent attachments
  • evap_out-7
    evap_out-7
    Rear vent attachments, slot for top stiffener
  • evap_out-8
    evap_out-8
    Evaporator and vent attachment points
  • f56a
    f56a
    Back from the printer
  • f56e
    f56e
    Left side, temperature sensor
  • f56f
    f56f
    Temperature sensor
  • f56g
    f56g
    Aerosport NACA vent valve in place
  • f56h
    f56h
    Left side cabin vent scat tube attachment point
  • f56i
    f56i
    Right side clearances OK
  • f56j
    f56j
    Top view
  • f56k
    f56k
    There's just one problem....
  • f56b
    f56b
    Bulkhead adapter 3D printed in tough epoxy
  • f56c
    f56c
    Bulk attachment point
  • f56d
    f56d
    Bulkhead adapter in place
  • ba2
    ba2
    Bulkhead adapter design
  • ba1
    ba1
    Bulkhead adapter, left side view
  • ba3
    ba3
    Bulkhead adapter design
  • f56l
    f56l
    Printing the bulkhead adapter prototype
  • f56m
    f56m
    Finished bulkhead adaptor prototype
  • f56n
    f56n
    TPU is very flexible
  • f56o
    f56o
    Top view with bulkhead adaptor prototype in place
  • f56p
    f56p
    Checking bulkhead adaptor prototype fit
  • f56q
    f56q
    Side view of bulkhead adaptor prototype

 

 

Inlet plenum progress [2.0 hours]

Construction work has been spotty for the past few months due to some work commitments. Time to catch up on a few posts.

I received the prototype 3D printed inlet plenum, after a very long delay caused by Covid-19, a shipment lost in customs, reprinting a replacement, more shipping delays etc. This part was printed in ASA material by a vendor in Sweden. Quality is good apart from some areas where the wall thickness should have been greater.

The part fitted perfectly around / through the compressor, the air filter shroud mount etc. The inlet ramp was also good, perfectly horizontal and lined up with the opposite side (standard Showplanes fiberglass plenum) within 1mm, which is good enough for me. The front edge of the inlet ramp is too far forward, requiring me to trim too much of the cowling. While it would work, it doesn’t leave as much of the cowling inlet hole as I’d like, to get nutplates and some sort of overlapping seal in there. This is one of the areas where the wall thickness is also a bit low. Clearance on the bottom side to the cowling is good, a bit over 1/8″ at the closest point. The rear scat tube connection for a heat muff is also good.

Overall, close to a hole in one which I’m relieved about given how complex the part is. I can now proceed to finish the front of the baffles and around the governor. I’m going to need to address the wall thickness issue and trim back the front edge, which means re-printing the part. These are simple adjustments but I’m going to also look at whether any better alternatives exist than the ASA material I’ve used.

It’s really hard to see much from the pictures, because the 3D printed part is black, but they show the general idea.

  • f55a
    f55a
    Prototype inlet plenum in place
  • f55b
    f55b
    A/C fitting clearance OK
  • f55c
    f55c
    A/C fitting clearance OK
  • f55d
    f55d
    Prototype inlet plenum in place
  • f55e
    f55e
    Good fit around A/C and into air filter shroud
  • f55f
    f55f
    Good fit around A/C and into air filter shroud
  • f55g
    f55g
    Horizontal, and about 1mm below right hand side plenum - good enough

 

Skybolts [7.5 hours]

I installed the top cowling Skybolts.

Since I didn’t use the Skybolt flanges, I needed to drill out both the cowl and the custom built flange holes that I’ve been cleco’ing so far for holding the cowl in position. I used a step drill to take a section of holes out to 15/32″, removed the cowl, and drilled the flange holes further to provide enough clearance for the retainers. A tapered hand reamer is handy for touching up the 15/32″ cowl holes slightly to fit the rings.

I used floating retainers for the lowest position on each side. These allow a bit of up/down movement, not sure they were necessary but I put them in anyway as they were part of the kit.

  • f53a
    f53a
    Installing Skybolt retainers
  • f53b
    f53b
    Installing Skybolt fasteners
  • f53c
    f53c
    Every second fastener done
  • f53d
    f53d
    Most done
  • f53e
    f53e
    Clamping retainer prior to riveting
  • f53g
    f53g
    All Skybolt retainers installed
  • f53h
    f53h
    All Skybolt retainers installed
  • f53f
    f53f
    Skybolt fasteners complete

 

Cowling bump, oil door etc. [16.5 hours]

While waiting for the 3D printed inlet plenum, I went back to complete a few cowling jobs.

The hole that I cut out of the lower cowling to clear the A/C compressor needed to be filled in. To do this, I taped a 1/4″ thick cardboard spacer in front of the A/C compressor, then applied play-doh to build up a shape that looked aerodynamically reasonable. I applied more masking tape over this, and then packing tape to act as a release agent. I then took the bottom cowling off, and applied two layers of fiberglass cloth over the taped off area. Once this cured, I pried it off, trimmed the excess, and scuffed the resulting shape all over.

After removing the tape and packing, I epoxy’d and cleco’d the shape piece in place, turned the cowl over, applied thickened epoxy to fill the gaps around the cutout, and then applied two layers of glass cloth over the entire inner area. Once cured, I applied a layer of micro to the outside, and sanded it back to form the final shape. There were a lot of crater sized pin holes and these will have to be filled, apart from this the A/C compressor bump on the lower cowling is done.

I also did the oil door. I stiffened the door with a piece of 0.063″ Alclad,  bent into shape by hitting it with a rubber mallet. In retrospect, I should have either drilled some lightening holes in it or perhaps 0.032″ would have been OK, the door is quite heavy. I used a pair of Cessna KM610-64 Camloc’s for the catch, building up the button area with thickened epoxy to match the oil door thickness.

I also fitted the Aerosport RV-10 emblem covers to the cowling halves. Just follow the instructions, being careful not to epoxy the cowl halves together anywhere except where you intend to.

  • f52a
    f52a
    Taped 1/4" cardboard spacer in front of A/C compressor
  • f52b
    f52b
    Essential materials
  • f52c
    f52c
    Building up the shape
  • f52d
    f52d
    Taped up with packing tape
  • f52e
    f52e
    Two layers of glass cloth
  • f52f
    f52f
    Trimmed shape in place
  • f52g
    f52g
    Applied two layers of glass cloth to inside cutout
  • f52h
    f52h
    After one round of micro, needs more work
  • f52j
    f52j
    Oil door and stiffener plate
  • f52i
    f52i
    Alclad plate to stiffen oil door
  • f52k
    f52k
    Setting stiffener plate in place
  • f52l
    f52l
    After epoxy set
  • f52m
    f52m
    Drilling oil door hinge
  • f52n
    f52n
    Drilling holes for release catches
  • f52o
    f52o
    Release catch buttons built up with thickened epoxy
  • f52p
    f52p
    Release catches in place, roughly sanded
  • f52q
    f52q
    Release catches in place, roughly sanded
  • f52s
    f52s
    Stainless steel catch plates in place
  • f52r
    f52r
    Almost completed oil door
  • f52t
    f52t
    Glassing in Aerosport templates
  • f52u
    f52u
    After curing, with holes drilled and template punched out
  • f52v
    f52v
    After initial cut
  • f52w
    f52w
    Aerosport emblems in place

 

Why we have children

Reason number 101:

A couple of months ago I bought a pair of long stroke 3000kg hydraulic jacks, because I knew that “soon” I was going to have to jack the fuselage to finish some jobs on the main gear and do the wheel spats. After that I would need to be able to safely jack the entire aircraft for ongoing repair and maintenance.  I reviewed a thread on VAF that contained various pictures of how builders had made Jack Stands, to provide stability for the Jacks and reduce the chance of a disaster.

I also bought some Jack Pad adapters from Bogert Aviation, these screw into the wing tie down points and provide a non-rigid jack point. The Jack Ram adapter didn’t fit on my Jacks, the adapter was larger than the Ram diameter, but there were a pair of grub screws to secure it.

I asked my eldest son – who works in industry and has done a lot with metal – if he might have some scrap plate lying around that I could make a few base plates from, and showed him the pictures on VAF. He said “leave it with me”, and some time later came over and picked up a Jack.

The other day he brought over the most awesome pair of Jack Stands I’ve ever seen, complete with routed out base plates, welded supports and a two section collar that bolts together to retain the Jacks. He also had a pair of adapter rings, which perfectly fitted the Bogert Jack Ram adapters to the Jacks.

I’m now all set to Jack the airframe. What else can I say?

  • f51c
    f51c
    Awesome Jack Stands
  • f51e
    f51e
    Base of stand sits in routed out recess
  • f51f
    f51f
    Welded struts secure collar to base
  • f51d
    f51d
    Collar around Jack Body
  • f51a
    f51a
    Sleeve to mate Bogert Jack Ram Adapter to Jacks
  • f51b
    f51b
    Adapter sleeve in place
  • f51g
    f51g
    Bogert Aviation Adapter and Jack Pad

 

Compressor stall [105.0 hours]

Over the past month I’ve had to deal with something that was always going to stop the project dead in its tracks – sorting out how to mount an Airflow Systems A/C compressor inside a Showplanes cowl. The main problems are:

  • The A/C compressor doesn’t fit – it smashes into the cowl
  • The A/C compressor occupies almost all of the space normally used for the left hand air inlet plenum

I’ve seen other build efforts that range from leaving out the left hand induction air plenum entirely, to an A/C compressor mount position that occupies a good part of the area of the left hand inlet duct – in turn compromising the cooling air for cylinders #2, 4 and 6.

Recent efforts in Australia, such as this one, use a longer arm on the A/C mount to drop the compressor down low, and make a bump on the bottom cowling to suit. Armed with the latest mount kit from AFS, I proceeded to test mount the A/C compressor, and immediately ran into quite a bit more trouble than I had expected.

Tensioner wheel, bracket

The supplied drive system simply didn’t work. The tensioner (idler) wheel, using the supplied bracket, hits the starter motor. I can see that with the previous “short” arm, the system would  swing up higher and that would free up enough room for the idler wheel to swing past the starter motor. I sent feedback to AFS about this but received no reply. After consulting with the Australian builder referenced above, it turns out the solution was to:

  • Add spacers, for a total of 7/16″ of spacing, to the engine mount. This moved the entire compressor assembly “away” from the starter motor by 7/16″.
  • Machine a replacement idler pulley, which was the same size as the AFS supplied pulley, but without the ridges on each edge – saving around 1.5mm of edge distance.
  • Make a longer arm, even longer than the “long” one AFS supply

I started making up additional spacers (AFS supplies three 0,063″ spacers), using 0.063″ Alclad, but I was only able to add two of these before I ran out of threads on the engine studs used for the A/C mount. I didn’t want to replace these studs, and I didn’t want to switch over to low profile lock nuts – the A/C compressor is quite heavy. So, my spacing limit without resorting to these measures was 0.3″.

The guy who did the VH-BKK installation referenced above graciously had another idler pulley made, and sent it down to me. Armed with this, I still needed to change the position of the idler mount, which means I have to build a new idler mount bracket. I’ve ordered some 6061-T6 plate to do this, in the meantime I drilled a new hole in the existing bracket (rendering it structurally unsound) just to prove I have the hole position correct. This is shown in the following picture, along with the new idler pulley. The clearances everywhere around this are very small, but this is typical and they will be adequate. The idler pulley can now swing up past the starter motor with about 1.5mm of clearance.

I also had to change the Serpentine belt, for this arrangement I fitted a 4PK1130 belt, rather than the 4PK1113 belt provided with the kit – just 17mm longer.

It is necessary to cut out a section on the front of the Showplanes cowl and fiberglass a bump in place to provide adequate clearance for the front of the A/C compressor. There’s nothing hard about this, and one good thing about the Showplanes cowl installation is that the Serpentine belt does not overlap the inlet at all (unlike with the Van’s cowl) – so there is no air leakage associated with treatment to clear the Serpentine belt, and no compromise to cooling air inlet area.

  • new_idler_bracket
    new_idler_bracket
    New location of idler hole (dimensions in mm)
  • f50i
    f50i
    Modified tension pulley position

LHS Inlet Plenum

I had expected to solve this problem with various cuts and balloons etc. to the existing inlet plenum. After looking at the problem, I didn’t even attempt it because (a) this was going to beyond my fiberglass skills, and (b) this is probably beyond anyone’s fiberglass skills. There simply isn’t a clear enough path through the maze to make an adequate shape, and unless I could turn the plane upside down, gravity was always going to work against me.

After some soul searching, which included consideration of leaving the A/C system out, I decided to go ahead and create a 3D model of the entire system as a means to 3D print a replacement inlet plenum. The top end is identical to the Showplanes system, using the lower 1/3 of the circular inlet hole for induction air. The plenum has to step down and change shape, wrap around the bottom of the A/C compressor while clearing the bottom cowling, and then join in to a replacement shroud around the existing Showplanes air filter system. Here are some screenshots which include various early prototypes and the final model, which includes an air takeoff to account for the standard Van’s 2″ scat tube outlet for air to a heat muff.

  • ip1
    ip1
    Early model - rear view, showing heat muff scat tube attach point
  • ip2
    ip2
    Early model - Front view, without compressor
  • ip3
    ip3
    Early model - top view showing heat muff air inlet - slot is for Van's supplied mesh screen
  • ip4
    ip4
    Early model - left side view showing heat muff air inlet - slot is for Van's supplied mesh screen
  • ip5
    ip5
    Early model - Induction air inlet, detail showing clearance for Serpentine belt and A/C compressor lug
  • ip6
    ip6
    Early model - Rear view with A/C compressor model in place
  • ip7
    ip7
    Early model - Top view with A/C compressor model in place
  • ip8
    ip8
    Early model - Right side view with A/C compressor model in place
  • ip9
    ip9
    Early model - Front view with A/C compressor model in place
  • f50g
    f50g
    Inadequate clearance for botton A/C fluid connection (early model)
  • f50h
    f50h
    Prototyping with small sections taped together
  • f50f
    f50f
    Prototyping with small sections taped together
  • ac_hole
    ac_hole
    Location of A/C cutout in Showplanes cowl
  • lhs_inlet_view1
    lhs_inlet_view1
    Final model
  • lhs_inlet_view2
    lhs_inlet_view2
    Final model - Serpentine belt and A/C compressor lug clearance
  • lhs_inlet_view3
    lhs_inlet_view3
    Final model - Rear air takeoff for heater SCAT hose
  • lhs_inlet_view4
    lhs_inlet_view4
    Final model - Air filter shroud, note drain hole provision at bottom
  • lhs_inlet_view5
    lhs_inlet_view5
    Final model - Viewed from bottom front
  • lhs_inlet_view10
    lhs_inlet_view10
    A/C clearance (note: not fully rendered)
  • lhs_inlet_view11
    lhs_inlet_view11
    A/C clearance (note: not fully rendered)
  • lhs_inlet_view12
    lhs_inlet_view12
    Bottom showing fluid connections (note: not fully rendered)
  • lhs_inlet_view13
    lhs_inlet_view13
    View showing clearance for fluid connections (note: not fully rendered)
  • lhs_inlet_view14
    lhs_inlet_view14
    Separate shape under design for attachment around Governor

The inlet plenum as shown can be 3D printed in one piece. It is secured at the bottom by three screws in the LH air filter shroud, using nutplates, same as the standard Showplanes arrangement. Around the compressor, two places mount to the A/C compressor lugs using Buna-N rubber spacers, AN3 bolts and washers. The vibration-damping spacers are rated to 200 degrees F which should be adequate. At the top, a flat Alclad plate which extends down from the existing #2 cylinder mounting flange is secured across the heat muff air inlet area, and at the very front of the inlet, using #6 countersink screws with nutplates on the underside of the inlet plenum. One of the front positions uses a low profile nut, embedded in a hex shaped hole, instead of a nutplate.

For the plenum material, the choices are currently between UV resistant ASA, or the more expensive UV resistant tough resin. Both have high glass transition temperatures and adequate chemical resistance. The plenum does not extend back too close to cylinder #2.

To prototype the system, I printed the plenum in sections on my cheap consumer grade 3D printer, using PLA, and taped the parts together. It takes about 100 hours of printing time to do the complete model, and I’ve made several revisions to refine the design and fix up the various maths mistakes I made along the way. It’s been a laborious process but I’m happy enough with the end result. It takes a high end desktop platform 15 hours to render the model in suitably fine detail, and a bit of repair processing to derive the final STL file. I uploaded the (64MB) STL file to http://www.craftcloud3d.com and was quoted just over U$200 to print the model in Black UV resistant ASA, with 40% infill.

Just today I pulled the trigger and ordered the final article, it’s being printed by a vendor in Sweden, and will be delivered here within two weeks. There is still a chance that the final piece will require some small adjustments. There’s a limit to how far I can go with taped together sections, and how many times I can re-measure everything. The final model is way more complex than I had expected, and has consumed far too much time, I’m tired of fretting about it so it’s a relief to get it off my desk.

In the meantime, there are a few other, much simpler pieces I can design to help with the baffling around the governor etc. I’ll complete these, but mostly I’ll be getting back to actual, real, physical work on the project – there is a lot still to do.