Justin's Raven Build (now engine change)

[heisan]

Just a brief update. After months of waiting, the various FWF bits arrived from Oz. The Jabiru factory just ran the engine in the test cell, and according to Giel, it is the best he has seen yet - a solid 2900RPM on the test prop.

All the bits and pieces should ship tomorrow, and I will start fitting this weekend!

[Jean Crous]

Good to hear Justin ! Keep the foties coming.
J

[heisan]

Some action at last...

First, as a sideline, I have been making a new instrument panel. Need to improve maintainability, and fix some non-ideal ergonomics on my first one. Live and learn...

Here is the new panel in its mould:

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And the big fun - opening the boxes that arrived today!

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Still have some work to do before hanging the engine. New battery box is just about ready. New Jabiru air box does not quite fit - so I will need to 'edit' it a bit. Laid up the components for the oil catch bottle. And need to finish the panel. But the big things are the bits that go against the firewall, behind the engine, as these must all be fitted before hanging the engine. Will see how much progress I make this weekend.

[Jean Crous]

Happy for you Justin ! I am sure after this installation you will finally have what you want.
Jean.

[giarc64]

U must be super excited Justin

[heisan]

More progress, but it is surprisingly slow. Somehow (as usual) it seems like every task snowballs into a million smaller tasks - at least half of which require parts that I don't have and aren't easily available. But some things are happening.

Firstly - the new instrument panel is taking shape:

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This is the main sub-frame. This contains the main electrical panel, engine controls (dual throttle mechanism, choke and carb heat controls), and supports the main instrument panel and radio panel. Should be a huge improvement in accessibility and maintainability. I hope.

The engine is now mounted on a mock firewall/stand. Difficult to see, but all firewall attachments are marked to make it easier to lay out the firewall forward kit at home.

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I was hoping that the stock Jabiru air box would fit - but it is just too long to fit anywhere on the firewall.

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Fortunately, non-structural composite work is easy - simply cut-and paste. First, cut the carb heat box off the main filter box, and patch up the gaps. I had a carbon fibre sheet that I laid up previously for a test, so I just cut this up, and used this and some 5-minute flox to put it all together.

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Now I can play with the positioning of the two:

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This looks good. Best possible alignment with the carb inlet, straight shot to the muffler for carb heat, and the cowl for a fresh air inlet. Just want to take it to airfield and check it out there - unfortunately, I did not mark the fuel tank position on the mock-up, so I am not sure where I will have access for the carb heat cable.

The main problem, is that no way how I do this, there just isn't enough space for the airbox with the gascolator on that side - so that means the gascolator, stiffener, and exit baffles must all move - which will cost another day at the airfield .

I hope to put in some leave this week, and see how far I can get.

[heisan]

I really need to get to the airfield to do the final fitting of the instrument panel and airbox, so that I can finish those off. Also need to strip off the gascolator and stiffener so I can start moving them. With any luck, I will be able to take leave on Wednesday to do this, and start making real progress again.

Until then, I have just been finishing off some small bits on the instrument panel.

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Mechanically pretty much complete now. Just need to do the final trim and fit so I can finish it off. Seems to be working quite well so far. And those wooden cabinet knobs seem to make quite good looking throttle knobs .

[Scotsman]

Looking good Justin. You are going to have to teach me how to do this fibre glass and carbon fibre thing as it is always a f%$k up when I try it.

Going to be great to see your aircraft in the air again as it will have bags of spare power this time.

[Induna]

I am very curious to see the performance of this 120HP engine in this raven...

Justin, do you have the speed wings?

Jacques

[heisan]

I am very curious to see the performance of this 120HP engine in this raven...

Justin, do you have the speed wings?

Jacques

I am curious too . Yup - have the speed wings on. With standard wings, the VW would still be in...

[heisan]

Even though I have done it before, it still got me... The seemingly endless number of small tasks involved in even a 'simple' change like this.

So far, I have most of the FWF bits and pieces finished, and ready to install.

I have also stripped most of the old FWF stuff, and blanked of the old holes in the firewall. Most of the new stiffeners are fitted, as well as the gascolator and air guides. Most of the fuel plumbing is done, but I still need to remake one pipe for the new gascolator position. Still need to fit the air box, battery and relays.

Here are some pics of the progress so far.

Finished (hopefully) airbox (serious cut-and-paste hob here):

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Engine with oil cooler fitted, rivet flange for oil cooler duct and nearly complete ram-air ducts:

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Instrument panel with all mechanical bits, and avionics powered up. Still need to add 3 airframe connectors and radio panel:

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The disaster zone behind the panel. Using a sub-frame for the main electrical connections is probably a good idea - but it does get a bit busy. Decided to do away with all the steam guages - so it also has a backup battery and charger. Xtreme is on a separate electrical bus with battery backup.

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[heisan]

Last night I was trying to work out where all the time goes. Each evening, I work 2-3 hours in the garage (engine and fitment), and another 2-3 hours inside (instrument panel). And yet, I don't really see much progress.

So I made some notes last night. Got into the workshop at 19h30, and worked there until 22h10 (2 hours and 40 minutes). Started by finishing the fit (trimming internal baffles) on the right air duct. Then marked and drilled the mounting holes. Discovered that two of the holes were extremely close to the edge, even with the ducts flush against the tappet covers, so decided to add some reinforcing tabs to make sure they can't tear loose. Measured up, cut, drilled, filed and sanded 6 tabs, as well as 2 spring brackets. Floxed and riveted all 8 in place.

Total time 2 hours and 40 minutes, and I covered exactly one page from a 83 page installation manual...

[Zak]

That sound familiar - working a whole weekend and having only a few brakets to show for it.

At least its done now 6 down xx to go.

[heisan]

Some belated updates. Slow (but steady) progress being made.

Just about done with all the goodies that go on the firewall behind the engine. All of the old holes plugged, and new fittings in place:

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Test fitting panel - mainly for cable lengths and routings. All still looking good.

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Busy with AVDALSR085 - I hate the CHT sensors under the plugs... Unfortunately, my mains powered Dremel packed up, and my battery powered one only has enough juice to do two heads at a time...

First remove plugs and head bolt, and (thoroughly) cover the holes:

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Now viciously assault it with the Dremel, until the CHT probe fits snug against the head. Tap and drill the hole, and presto:

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Finished product:

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[heisan]

Testing the CHT probes by heating the bolt, to see how accurately/reliably these little lugs conduct heat to the thermocouples:

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While heating them, you can see a little lag. The sensor closest to the flame picks up quickest, and the ones at the other end also pick up quicker (direct contact with the head of the bolt), but the heat does conduct fairly well through the entire stack:

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Wait a few seconds after removing the flame, and all six senders match exactly:

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Basically, I would say the sensors all work perfectly, and track the actual bolt (soon to be cylinder head) temperature within seconds.