My "Old 102" Build

Discussion in 'Plane Registry' started by david010567, Mar 9, 2008.

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  1. Nov 24, 2010 #2301

    david010567

    david010567

    david010567

    aka Schlawiener

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    So... I now have all the parts for the DA-85 retrofit. Kevin at Jtech did me right with the custom muff. He even put a third stack in there for better breathing.

    Received the Sierra Giant scale prop shaft extension and drill guide. Received the ignition battery eliminator from TBM. Also got the DA recommended Menz 26-10 break-in prop and exhaust gaskets from DA.

    So what oil should I be using? LOL!
     

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  2. Nov 24, 2010 #2302

    GravyGoodness

    GravyGoodness

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    Huck-O-What?

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    Oooh, pretty. I bet you'll love it in that bird.
     
  3. Nov 24, 2010 #2303

    BRUTUS

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    BRUTUS

    Plank Junky Lifetime Supporter

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    Nice pipes! Low passes are going to sound sweet with that thing!
     
  4. Nov 30, 2010 #2304

    david010567

    david010567

    david010567

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    Not much progress...

    I drilled out the Menz 26/10 prop front and back using the drill guide. Got the spinner back plate drilled. Using various layers of the best aircraft plywood available, I made the engine standoff block using the cutout template provided by Desert Aircraft. I'm a tiny bit short of where I want to be with the spacing of the spinner and the nose ring of the fuselage so I put a layer of heavy glass cloth on the the new firewall and standoff.

    FYI... After making biscuits for breakfast... Turn the oven off and just pop in any of last nights glass layup's until room temperature for a nice post cure. hehehe.

    Gotta come up with a plan on how to hang the fuselage nose up in my shop. grrrr!

    The plan is to drill for a few 6-32 bolts and blind nuts to temporally attach the new firewall to the old, Hang the fuse up, bolt the engine to the standoff block using 1/4-20 nylon bolts and epoxy the unit in place. Once cured... I should be able to unbolt the engine and firewall to finish drilling the engine mounting bolts.

    Wonder how long the 1/4-20 nylon bolts would last if the engine was running?
     

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  5. Nov 30, 2010 #2305

    TManiaci

    TManiaci

    TManiaci

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    About two flips....
     
  6. Dec 1, 2010 #2306

    10+

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    Professional Moderator

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    Hey,, You can use some tape and a 6' ladder to get your bird nose up safely. I have done it and it works great. Just make sure neither the ladder or plane can fall over...
     
  7. Dec 1, 2010 #2307

    david010567

    david010567

    david010567

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    Tape? Tape??? U serious???
     
  8. Dec 1, 2010 #2308

    david010567

    david010567

    david010567

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    Got the spinner cut today... Any time you can do this job without loosing an eye or a finger is a good day.
     

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  9. Dec 2, 2010 #2309

    david010567

    david010567

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  10. Dec 6, 2010 #2310

    david010567

    david010567

    david010567

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    Hysol will be here Thursday so I have 3 days to figure out how to hang this Schmitt nose up so I can locate the engine bolts. I drilled (10) holes through the new firewall and used wood screws with washers for clamping. The screws + the (4) engine bolts should be enough clamping to make a good lamination.
     

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  11. Dec 6, 2010 #2311

    david010567

    david010567

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    Here is my plan... Hang the fuselage by the wing bolts and use my table to keep it from flopping over. I should be able to tape a pillow to the edge and use the table to stand on to center the engine. Open to all ideas here????
     

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  12. Dec 6, 2010 #2312

    stang151

    stang151

    stang151

    Pucker Hucker

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    Is there enough room to use an "L" bracket from the wing bolts to the table? Have done this before ..don't know your clearance.
     
  13. Dec 9, 2010 #2313

    david010567

    david010567

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    Ground Control to Major Hans... Commencing countdown, engine on...
     

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  14. Dec 13, 2010 #2314

    david010567

    david010567

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    Here is some progress pictures of the engine, muffler mounted. The hatch needs a little more trimming to make room for the "Shaky Shaky".
     

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  15. Dec 13, 2010 #2315

    david010567

    david010567

    david010567

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    Once I rework the hatch around the muffler, cut the stacks, and seal up the hole where the power ram was... It will look a WAY better than I ever expected. Don't ya love photoshop?
     

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  16. Dec 16, 2010 #2316

    BRUTUS

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    Plank Junky Lifetime Supporter

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    LOL I like the pipes! Reminds me of some old rednecks Kenworth with HUGE chrome stacks!

    Looking Good David- once you get it running you need to post some video so we can hear her ROAR!
     
  17. Dec 17, 2010 #2317

    david010567

    david010567

    david010567

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    Thanks Bro... I'm trying to concentrate on only the stuff I need to get done to fire it up. I'm on stay-cation between Christmas and New Years so I really want to get some good tuning time and quality flights.
     
  18. Dec 27, 2010 #2318

    david010567

    david010567

    david010567

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    Ignition module is mounted on foam and secured with Velcro straps per DA-85 instructions. Ignition Battery Eliminator (IBE) unit is mounted to the firewall using Amazing Goop. Ignition wire insulated with plastic wrap. All cables secured.

    Stacks are cut, muff is final installed with exhaust gasket, bolts are installed with Loctite thread locker. All grade 8 engine bolts are installed with lock washers and nylock nuts using socket and box end wrench. (man tools) Yeah!! Ignition leads are secured and we're Hot!
     

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  19. Dec 27, 2010 #2319

    david010567

    david010567

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    Tell ya what... Going from a single 1/4" firewall to a Hysol laminated 1/2" thick firewall makes the engine totally solid. No flex at all... Nada.
     
  20. Dec 29, 2010 #2320

    david010567

    david010567

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    Throttle and choke linkage are adjusted, fuel tank and fuel lines secured. Both low and high needles set to 1-1/2 turns... ROLL TIDE!!
     

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