The headrest is all finished now - bar the painting.
Same deal with the thigh covers for the seat - again these need painting but the Dzus fasteners are all in place.
The firewall is also starting to get there. The Fibrefrax is all done on the front facing part - just waiting on the thinner Fibrefrax to do the outside of the fuse.
Onto the battery and so the start of the electrics - which I think is going to be a lot of work.
I've got that '90% done, 90% to do' feeling...
The battery fits very snugly in it's mount and the same goes with the cover.
I've figured out where I want the master contactor to go - and I'm starting to figure out the route for the battery cables.
The contactor needs a diode adding (this is to protect the circuit from the momentary reverse flow when the master switch is thrown). Easily done with a couple of crimps and some heat shrink. Remember to have the diode facing the right way! The grey bar on the diode goes towards the Batt (large pin) end.
Regarding the location of the contactor - something I learned from my LAA electrics course is that in an aerobatic aircraft the contactor should not be mounted vertically. This is because under very high G the contactor internals can be driven downward so much that it switches off - thereby cutting all electrical power. This most likely happens at very high G levels which the Twister will never see but it is good practise to mount the contactor horizontally anyway.
Onto the headset jacks.
These seem the most archaic things in aviation - not available with a crimping style of terminal like everything else these days - instead you have to solder on the wires. This seemingly simple job took me a few hours as my technique was a bit crap with soldering. Got there in the end and I'm pleased with the result - don't forget to put the heatshrink on and support these wires well at the terminal end as they are quite fragile.
When is someone going to design a crimping style jack? There would be a huge market for them.
Next jobs are to continue on with the battery cable and other electrics.
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| Bottom of seat - showing areas carved out ready for 2 layers of carbon. |
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| Fibrefrax all done on the firewall area. |
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| Headrest all done. (Bar painting). |
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| Underside of seat with Dzus fastener springs riveted in place. |
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| Thigh covers all done - except painting. |
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| Battery in it's mounting. |
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| Battery with the cover on - very secure and snug. |
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| Master Contactor location and first battery wire sized up. |
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| Contactor with Diode added. |
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| Headset jacks all wired up. |
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