For insulation and soundproofing I used a aluminum air bubble film foil. This weighs nearly nothing and should give good insulation. Fixing of the foil on the back is with Velcro-strips. My wife wants another look so I will be cover the foil with car roof lining materialContinue Reading... Comments Off on Foil for rear wall
Since I am still waiting, I started doing minor things. One of these was a rear wall, which I wanted to have to make sure no luggage goes into the back. I fabricated this from Airex C70 and glassfibre. Very stiff and very lightweight. Picture shows the raw wall, it will be cased later with […]Continue Reading... Comments Off on Rear Wall
The inspector advised to install an flap indicator. With the standard setup it was not possible to make appropriate markings. An aluminim strip above the installation makes it possible to mark the flap positions. The Rebel standard positions are in increments of 6 degrees. For the sake of simplicity I marked the positions in 10 […]Continue Reading... Comments Off on Flap Indicator
I received the ballistic recovery system from Junkers Profly and started installation of rocket, container and harnesses. The picture above shows the holding point for the backward Aramid harnesses. Picture below shows the harnesses from above. I will protect them with 0.015 Aluminum strips later on.Continue Reading... Comments Off on Rescue System Harness
As required by the VLA and EASA specifications I needed to install a fireproof identification plate. I decided to install it near the left fin. For marking I used a fireproof stainlees steel plate engraved by laser. This laser engraving is available via Internet.Continue Reading... Comments Off on Identification Plate
We reserved a registration number for the Rebel: D-EREB. We used a printed foil to put the numbers on the plane. The plane will be painted later, but to get the permission to do the first start, we need the plate. So we put them on and they will be redone later after painting. […]Continue Reading... No Comments.
Before the engine even had a single minute on it, I had to do a service bulletin from Rotax. The carburator floaters had to be changed, since there were production errors. Easy job if the carburator is freely accessible.Continue Reading... No Comments.
Seats are ready. A local upholstery did it for us. We took care they are not too thick, cause I am very tall. Otherwise I couldn’t have an easy look out. This is how the cabin looks like now. It is really spacious. Enough room for luggage.Continue Reading... No Comments.
Cowling is now near to completion. Spinner and prop are installed. I am preparing for the first engine start. But I have to move the plane first to be able to install the wings with the tanks.Continue Reading... No Comments.
Dashboard is nearly complete now. Only transponder is missing, this will be installed just before the first flight. On the right side you can see the IPad we will use for navigation.Continue Reading... No Comments.
We acquired and installed the radio. We bought the KRT 2 model from Dittel-Avionik. Nice radio, not too expensive (compared to others). Of course ready for the upcoming 8,33 KHz spacing in Europe. I do not have the radio permission yet, will buy this when I start testing. So antenna is not connected yet and […]Continue Reading... No Comments.
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 […]Continue Reading... No Comments.
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 🙂Continue Reading... No Comments.
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.Continue Reading... No Comments.
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 […]Continue Reading... No Comments.
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.Continue Reading... No Comments.
EGT Probes were also welded to the exhaust, 10 cm behind the cylinder. We installed two probes in the two backside cylinders.Continue Reading... No Comments.
A friend welded the exhaust for me. He did a really great job. The TIG-welded parts look great.Continue Reading... No Comments.
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.Continue Reading... No Comments.
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 […]Continue Reading... No Comments.
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.Continue Reading... No Comments.
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 […]Continue Reading... No Comments.
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) […]Continue Reading... No Comments.
The improved fibre glass fairing is done. Gives a much better appearance and is aerodynamically better. The biggest advantage is that there is no fear to loose this fairing. It nearly fixes without any screw. The next pictures shows the fabrication stages of this part. It’s always a great fun to work with glass […]Continue Reading... No Comments.
I was not to happy with the aluminum version of the front fairing. I think aerodynamically it is not the best solution. So we started to fabricate the front fairing from fibre glass. The picture shows the start with peel-ply as the last layer.Continue Reading... No Comments.
This is the fairing on the underside of the elevator.Continue Reading... No Comments.
Some details still have to be done. One of this is the tail fairings. Picture shows the elevator fairing made from aluminum. This fairing part is not so easy to fabricate. You have to bend it yourself from a sheet of 0.016 aluminum. You can also see the small aluminum fairing at the front. This […]Continue Reading... No Comments.
The ELT antenna is mounted near the ELT position. Cable can stay inside the recovery system compartment and the already existing doubler is strong enough to take the antenna root.Continue Reading... No Comments.
Since I am building a german Echo-class airplane, an ELT (Emergency Locator Transmitter) is mandatory. This ELT has an acceloremeter inside and can detect a crash. After activiation it sends out a signal on 406 MHz as well as on 121,5 MHz. Satellites will detect this signal and a rescue mission is started. I bought […]Continue Reading... No Comments.
I considered several positions for the ELT. I decided for a place in the compartment for the recovery system. There I built a special bracket out of 0.040 where the ELT could be mounted. As required this position is strong enough to take the ELT.Continue Reading... No Comments.