Author Archives: Thomas

  • Weight and Balance

    Posted on 24. August 2016 by Thomas in Miscellaneous, Recent Posts.

    With support from the local aircraft works, I did the weighing of the Rebel this morning. I am quite happy with the results: Although I installed a ballistic recovery system the total weight of the Rebel is 382 kg. I had 176 kg on every wheel in the front and 30 kg on the tail […]

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  • Fuel Return Line

    Posted on 6. April 2015 by Thomas in Fuselage, Recent Posts.

    As recommended by Rotax, we decided to install a fuel return line. This return line protects from vapor locks. It took some time to bend the appropriate 1/4 inch aluminum line. This lines starts from the firewall just below the main fuel line on the left side, then runs behind the mixer. As required all […]

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  • Spinner Problem

    Posted on 4. April 2015 by Thomas in Firewall Forward, Recent Posts.

    Trying to install the spinner, we experienced a problem with the propeller. The propeller already flares out in the radius of the spinner plate. We will have to figure out how to handle this. Spinner size can’t be reduced otherwise it does not fit to the nose cowl. Getting a different prop will be an […]

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  • Nose Cowl Work

    Posted on 4. April 2015 by Thomas in Firewall Forward, Recent Posts.

    The MC-7 nose cowl has nothing appropriate for the cowling doors to sit on. So I installed an aluminum strip along the edge of the cowl. The cowling doors can then sit on this strip. Fabricating this strip is not so easy as it looks, unfortunately is has to have appropriate curves to fit to […]

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  • Improved Flap Handle

    Posted on 4. April 2015 by Thomas in Controls, Fuselage, Recent Posts.

    Having nice wooden flight sticks, my wife also wanted an appropriate improved (better looking) flap handle. With the support of a friend in “wood business” I fabricated the wooden flap handle in the picture below. Much better looking, but only experimental builders can afford such a time consuming part 🙂

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  • Finishing Cowling

    Posted on 4. April 2015 by Thomas in Firewall Forward, Fuselage, Recent Posts.

    It was still rather cold in the garage. So we reduced our work in February and March. Nevertheless progress was made on the cowling. Picture below shows all parts of the cowling before riveting.  

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  • Test fitting spinner

    Posted on 26. December 2014 by Thomas in Firewall Forward, Fuselage, Recent Posts.

    All cowling doors are finished. So the first phase of the cowling is done. Before doing the final hole drilling I did a test fit of the spinner. It fits quite well. It’s not optimal, it could be 2 mm higher, maybe I can correct this when the rivets and screws are fixed. There is […]

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  • Cowling continued

    Posted on 26. December 2014 by Thomas in Firewall Forward, Fuselage, Recent Posts.

        We continued to work on the cowling. On the left side of the cowling we needed some more space on the underside due to the exhaust pipe. So I build a angle from 0.032 and used the shrinker to get a nice round contour where the cowling door will sit on.  

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  • First Cowling Door

    Posted on 20. December 2014 by Thomas in Firewall Forward, Recent Posts.

      After building the frame for the cowling, the doors are built. I did a mockup with posterboard first and then build the final door from 0.020 aluminum.

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  • Cowling Frame

    Posted on 8. December 2014 by Thomas in Firewall Forward, Recent Posts.

    After we received the spinner, it is clear how much space we need between the spinner plate and the nose bowl. So we could start constructing the cowling frame. I used 0.032 angles (8 of them) for the frame. The nose cowl has a 30 mm narrow strip from 0.032 aluminum installed around the flange. […]

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  • EGT Probes

    Posted on 2. November 2014 by Thomas in Firewall Forward, Recent Posts.

    EGT Probes were also welded to the exhaust, 10 cm behind the cylinder. We installed two probes in the two backside cylinders.

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  • Exhaust Welded

    Posted on 2. November 2014 by Thomas in Firewall Forward, Recent Posts.

      A friend welded the exhaust for me. He did a really great job. The TIG-welded parts look great.

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  • Heating Vent

    Posted on 2. November 2014 by Thomas in Instrument Panel, Recent Posts.

    Since our Rebel is heated by water, we installed a water vent inside the cabin (picture is behind the instrument panel). This vent controls the water flow to the heat exchange. I used a mechanical vent from a Volkswagen Bus heating. Incredibly cheap these auto parts.

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  • Carburater Heat Control

    Posted on 2. November 2014 by Thomas in Instrument Panel, Recent Posts.

    Placed the control knob for the carburator heat in the panel. Panel is now hopefully complete. In the picture you can see the starter key, on the right there is the switch for the electrical fuel pump, then the carburator heat. The poti on the right is the fan control for the heating. The two […]

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  • Bowdencable at Airbox

    Posted on 2. November 2014 by Thomas in Firewall Forward, Recent Posts.

                      Fixed the bowden cable for carburator heat at the airbox. Unfortunately Rotax did not have a proper end here for the bowden cable. So I fabricated a holder with a cable clamp to prevent the bowden cable from flipping back when pushing.      

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  • Radiator Mounting

    Posted on 5. October 2014 by Thomas in Firewall Forward, Recent Posts.

      It took me some time to find a good position for the water radiator of the Rotax. Most installations put the radiator to the front of the cowling. I couldn’t find an appropriate position at the front, so a decided to use the air outlet for the radiator. So picture shows the radiator mounted […]

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  • Fuel Line Routing Left

    Posted on 14. September 2014 by Thomas in Fuselage, Recent Posts.

      Picture shows the fuel line routing on the pilot side. It is not an easy routing because of the other tubes on the left side. Nevertheless it all fits well. I am missing some fitting, so the fuel valve above is not yet installed.

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  • Cowling Mockup

    Posted on 14. September 2014 by Thomas in Firewall Forward, Recent Posts.

    To check the design of the cowling I used cardboard to build a mockup. Cardboard will be replaced by aluminum later.  

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  • Nose Cowling

    Posted on 14. September 2014 by Thomas in Firewall Forward, Recent Posts.

      We decided to install the Thorp T-18 nose bowl (MC-7 from Aircraft Spruce). Its just a matter of design and this one looked best for us. The cowling itself will be fabricated from aluminum. I will adapt the design of other Murphy builders with the “4-door cowling”. The nose is rather big for the […]

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  • Transponder Antenna

    Posted on 14. September 2014 by Thomas in Electrical, Recent Posts.

                  Transponder Antenna is installed on the bottom of the fuselage. I installed a doubler inside.  

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  • Propeller

    Posted on 3. September 2014 by Thomas in Firewall Forward, Recent Posts.

    There it is, our propeller. I decided to go for a 3 blade ground adjustable propeller. It has a size of 1,82 m and should be good for our Rotax. It is made from Carbonfiber and looks really good. Manufacturer is GA-Prop, a finnish-ukranian company.

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  • Propeller Spacer

    Posted on 3. September 2014 by Thomas in Firewall Forward, Recent Posts.

    Propeller and prop spacer arrived today. Another important part of the plane. Since we want to use the MC-7 cowl from Aircraft Spruce we need a spacer for the propeller. This spacer puts the propeller 75mm  in front of the engine. Not yet finalled fixed in this picture.  

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  • VHF Antenna Including Doubler

    Posted on 14. August 2014 by Thomas in Electrical, Recent Posts.

      I decided to install the VHF Antenna in the tailcone. I think it is best for transmission (no wings disturbing transmission). A doubler (0.032) was installed in the tailcone to strengthen the base of the antenna. The antenna is from Sirio, type Taifun. Build in Europe, good quality, good appearance, cheap price. The next […]

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  • Headphone Jack Boxes Finished

    Posted on 14. August 2014 by Thomas in Electrical, Recent Posts.

    The headphone jack boxes are done on both sides. Today I finished the second box on the passenger side. We tested the connections and its ok. Easy to access on ground. Accessible also during flight.

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  • Headphone Jack Box

    Posted on 13. August 2014 by Thomas in Electrical, Recent Posts.

    I also did the headphone jack box today. I decided to go for two boxes, one on the pilot side (shown here) and an identical one on the other side.  I installed them in the back, just above the tubes. I am pretty happy with the result. This is a part a commercial builder would […]

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  • Left Side Exhaust Pipes

    Posted on 13. August 2014 by Thomas in Firewall Forward, Recent Posts.

        Picture shows the right side of the exhaust pipes. Before constructing and cutting them I had to fix the exhaust muffler. This was not easy since there is not really a good place to fix it. Adhesive tape (Tesa is my favourite) did the job. It looks a little bit strange, but the […]

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  • Exhaust Pipes

    Posted on 13. August 2014 by Thomas in Firewall Forward, Recent Posts.

    Today I did the exhaust pipes. This is a really exhausting job. Every piece needs to be measured and exactly cut. Picture shows the right side exhaust pipes. I fixed them with tape. A friend will do the welding job soon.

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  • Cabin Heater Installed

    Posted on 20. July 2014 by Thomas in Fuselage, Recent Posts.

    The heat exchanger from a VW sedan is installed at the passenger side. The two computer fans will be controlled by a power unit, which allows continous adjustment of speed. An adjustable valve in the connection to the engine will control the heated water flow. I hope this all gives a similar good control over […]

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  • Cabin Heater Construction

    Posted on 20. July 2014 by Thomas in Fuselage, Recent Posts.

    We are waiting for the cowling parts to arrive. Propeller and nose cowl are ordered, but it takes some time to get them. During the waiting time, we are doing some small stuff, which is nevertheless time consuming. We started with the cabin heat. Since we will use a water cooled (at least cylinder heads) […]

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  • Airbox Issue Solved

    Posted on 16. May 2014 by Thomas in Firewall Forward, Recent Posts.

      The Rotax Airbox did not fit to my installation at the beginning. The airbox conflicted with the motor mount. I long considered how to solve the problem. Discussions with motor specialists and the distributor followed. Some did not suggest a change to the original design. I solved the conflict by using 30 degree elbows […]

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