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budyerly(at)msn.com
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 Posted: Sun Oct 07, 2018 6:21 am Post subject: Advise wanted: route new wire bundle through tunnel |
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Marcel:
Most of my photos are in archive with the client files and are with them.
For a trigear conversion you can see that the belly hole was filled in with a flange on the inside, and then a recessed plate installed for a clean finish.
The hole I make in the tunnel area for access normally measures 6 inches wide by 8-10 inches long.
If the belly pan is stock, it is a very thin two to three layer panel on the belly and over time is no longer straight and smooth. I cut the hole, and build up the inside to fit my flush panel (normally .063 aluminum, or FRP or 1/8 ply) and glass it in from the inside. If the tunnel is sealed and work inside is impossible, I cut the access hole and make an exact copy and then cut the inside out (making a ring) for access to allow proper but tedious glassing of the flange.
On others for expediencies sake, I have just put a plate on the inside hollowed out as a flange, reduxed that ring to the inside and riveted it in to get a good bond. Then I fitted a plate for the outside to match the skin cut out to avoid the glassing. Install nutplates and used 525 screws to hold it in. The outer sheet metal cover is of .025 6061 aluminum and rests roughly even with the belly skin cut out. This is easy but what a bear to try not to cut into his wires laying all over the place in the belly. Much work with a flashlight and borescope to cut an initial round hole to prevent whacking his brake, fuel and wiring into shreds. We then tacked up his brake lines, repaired his brakes, and reran his wires. Get a creeper to lay on with a body lift or develop very strong stomach muscles.
Here is a photo of one a client did on his trigear conversion. He just left the old hole in place. After seening how I did my belly access, he installed his new firewall about 1.5 inches behind the nose gear frame where we put in a ply and glass firewall and covered with A/C Spruce firewall material (excellent stuff).
This access to the tunnel made the process of conversion of the tunnel quite comfortable.
Transformation of the mono to trigear tunnel is a piece of cake. Glassing and finishing was tolerable. I normally like the access hole to be a little further aft of the firewall to allow for the Fascet fuel pump to be moved where it is easier to service in the tunnel as shown in the second photo.
[img]cid:image001.jpg(at)01D45E27.81163A00[/img]
[img]cid:image006.jpg(at)01D45E27.81163A00[/img]
The belly hole allows for access to the brakes wiring, fuel selector, and wiring. Annual flashlight inspections are a breeze.
Hope that answers your questions. Don’t over think it, just do it.
Regards,
Bud
Sent from Mail for Windows 10
From: owner-europa-list-server(at)matronics.com <owner-europa-list-server(at)matronics.com> on behalf of zwakie <mz(at)cariama.nl>
Sent: Sunday, October 7, 2018 6:30:26 AM
To: europa-list(at)matronics.com
Subject: Re: Advise wanted: route new wire bundle through tunnel
--> Europa-List message posted by: "zwakie" <mz(at)cariama.nl>
Hi Bud, thanks for your suggestions as always.
budyerly(at)msn.com wrote:
> There is no easy solution
Yes, I came to that conclusion myself 
budyerly(at)msn.com wrote:
>
> 1. Make sure the com/transponder/vhf nav antenna wires are clear of the com and any current carrying wires.
> 2. Shield all the intercom and radio wires you can. Power and ground are not shielded normally.
Sure enough.
budyerly(at)msn.com wrote:
> 3. [...] clearly mark all the wires using permanent marking ties. (A zip tie thingy with a tab.)
>
For markings I use printable shrink wrap labels, that works very nicely.
budyerly(at)msn.com wrote:
>
> 4. [...] as fuel, brake, and wires are present and by adjusting the position of much of this you may cause a brake line leak, fuel line cut etc.
>
This was my reason for thinking before acting as this is my biggest concern also due to lack of 'easy' access: I only have two small panels where the tank outlets are (for fuel line replacement),. Unfortunately these are too small to get arms through far enough to reach the top of the tunnel. So maybe...
budyerly(at)msn.com wrote:
> Make a new access hole if necessary. I have one large belly panel and a smaller one at the rear
is the best thing to do first.
Where do you have that large panel, is it approximately where the landing gear is mounted, and and do you have a picture that you can share? (I could not find any picture on your website)
--------
Marcel Zwakenberg
XS TG || 912ULS || PH-SBR
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zwakie
Joined: 03 Aug 2009
Posts: 157
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| Posted: Sun Oct 07, 2018 7:13 am Post subject: Re: Advise wanted: route new wire bundle through tunnel |
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Hi Bud,
The setups in your photos is pretty much what I have, I was assuming you were referring to having an additional large access panel under the baggage bay / landing gear fixing area area. Probably I assumed this because the hard part is getting from appr. the "D" to that large panel between the seats. As most of the times, my assumption has proven to be the mother of.... (well, you know what )
Though not quite done thinking yet, I guess putting a (snakeskin?) sleeve around the bundle prior to working it through the tunnel will simplify the job and reduce the risk of damaging whatever is already there...
I will do as you say, next time at the airport I will start doing it.
As always, your advise is much appreciated!
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Marcel Zwakenberg
Europa XS TG || 912ULS || PH-SBR |
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budyerly(at)msn.com
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| Posted: Sun Oct 07, 2018 11:34 am Post subject: Advise wanted: route new wire bundle through tunnel |
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Marcel,
I did not put an access from below, to access the baggage bay. I put the access hole in the floor between the panels, so I can access the flap drive, and any wire bundles I need to run through the tunnel. I can use a large mirror to see and inspect well forward.
Under the fuel tank I have the stock access holes. All my customers have the elongated hole for access. Between that fuel access hole, the one in the baggage bay floor, the aft end between the seats from on top, and finally the large hole in my center tunnel makes the plane quite enjoyable to inspect and service.
There is nothing wrong with opening up the hump in the tunnel aft of the Mod 52 bar if you need to gain access. Just glass it back up or put in a flange and restore the structure for your trigear frames. I elected to simply put the hole (six inch hole with a ½ inch flange allowing 5 inches of round hole to see in there) in the floor and it allows easy access to my flap drive. I also made a large hole through the vertical support on the inboard port vertical support also to allow service.
See drawing of my typical baggage bay.
[img]cid:image003.png(at)01D45E53.23472A70[/img]
If I can put an access hole somewhere to allow maintenance and retain structure, I do it.
Regards,
Bud Yerly
Sent from Mail for Windows 10
From: owner-europa-list-server(at)matronics.com <owner-europa-list-server(at)matronics.com> on behalf of zwakie <mz(at)cariama.nl>
Sent: Sunday, October 7, 2018 11:13:11 AM
To: europa-list(at)matronics.com
Subject: Re: Advise wanted: route new wire bundle through tunnel
--> Europa-List message posted by: "zwakie" <mz(at)cariama.nl>
Hi Bud,
The setups in your photos is pretty much what I have, I was assuming you were referring to having a large access panel under the baggage bay / landing gear fixing area area. Probably I assumed this because the hard part is getting from appr. the "D" to that large panel between the seats. As most of the times, my assumption has proven to be the mother of.... (well, you know what )
Though not quite done thinking yet, I guess putting a (snakeskin?) sleeve around the bundle prior to working it through the tunnel will simplify the job and reduce the risk of damaging whatever is already there...
I will do as you say, next time at the airport I will start doing it.
As always, your advise is much appreciated!
--------
Marcel Zwakenberg
XS TG || 912ULS || PH-SBR
Read this topic online here:
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zwakie
Joined: 03 Aug 2009
Posts: 157
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| Posted: Sun Oct 07, 2018 2:15 pm Post subject: Re: Advise wanted: route new wire bundle through tunnel |
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My baggage bay arrangement is pretty much the same as in your standard layout, except that I do not have that 6 inch access hole with 5 inch access on the floor of the baggage bay.
That extra hole would make things a whole lot simpler (now and for future work and inspections), so that's what I will be going for. For the job at hand I think this will resolve my current issues/concerns.
Going off-topic: the builder of my plane has put a 4 inch hole in the starboard outer vertical support that always puzzled me as I could not find any reason for having that hole there. Reading your post made me realize that the builder probably had easy service in mind but got the inward and outward support swapped at install and either never realized his mistake or chose not to correct - funny how things go about huh?
Thanks again, you have been of great help Bud!
Marcel
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Marcel Zwakenberg
Europa XS TG || 912ULS || PH-SBR |
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