mtv wrote:I like it! Simple, but complete, and logical locations for everything. I hope you did away with the vernier throttle that Maule seems enamored with. Man, I hate those things!

MTV

Thanks.

And unfortunately (for yall), I'm keeping the vernier throttle. I don't mind them, have about 900 hours in bonanzas with them plus my time in my M7, never really bothered me. If you hold it right, you don't even notice you're pushing the button. Also the throttle cable was replaced in modern history so it's excellent condition. The other two I bought new.

Have been doing some wiring. Made a shelf on copilot side to hold some power distribution stuff. Alternator CB, JPI Ammeter Shunt, and my avionics ground block. Using a single point ground rather than bonding ground wires all over the panel/airframe should provide benefits down the line. I'll have one large ground wire running from this block to the airframe grounding studs you can see in the background on the tubes that will be against the firewall. The black thing is a dual USB port facing down. I'll use that for USB power I want more permanent/hidden. Like my GDL50 on the glareshield or if I put an ipad or something on the right side eventually. Keeps wires hidden.






Started on my radio/intercom harness but this was as far as I made before I realized I didn't buy single conductor 22ga unshielded wire, and I didn't buy Dsub pins for my intercom which I bought used. Will resume tomorrow when those arrive.

Yes, the vernier throttles are an acquired taste, but functionality is heavily dependent on the shape and function of one’s wrist. For me, holding that button in while landing requires wrist gymnastics that are uncomfortable and awkward at best. My current 175 has one of these, and I’m trying to work up the courage (and $$$) to replace it. Only other planes I’ve flown with them are Maules, and they didn’t seem as bad as the one in this plane….must be the angle required of the wrist.

Sometimes, I touch down and the button has relaxed just enough to lock, grrrrr. Not the time when I want to be focusing on adjusting my grip.

But to each his own. Your panel approach still looks good. BTW, I have a double USB outlet on the right side of my panel. I’m installing another on the left shortly. They are handy, and I dislike tangles of wires.

MTV

You all really thought that last panel design was going to stick? You clearly don't know me in person. Recut panels using the airgizmo mount I already had for the 660. Liked this a lot more so all the bare aluminum parts got dropped off at powdercoat friday



Started covering the rudder in oratex, in my dedicated Oratex room that probably started its life as a bedroom. In my quest for all new hardware, ordered new cable guides from Maule. Love new parts. Today I trimmed the first piece, put two coats of glue on it and the rudder. Glue will finish drying overnight and I'll hopefully stick it on tomorrow.

New Hardware


My oratex room


Initial trimming



While the glue was drying I got back to wiring harness. Really enjoying this.The radio connector is complete. On the intercom, I've got to do the rear pax headphones/mic cables and then I'm still waiting on more headset jacks and music jack to come in. The ones that came out of the plane weren't nice enough to solder back in when new ones are $3. That stuff is arriving Tuesday so hoping this will be done mid week. What you see below is about 12 hours of labor that I believe I could repeat in 6 hours. I did not skimp when buying tools and it has paid off. I've had exactly what I've needed to complete every step in a professional manner. My aerospace engineering background is coming in handy.



And of course, on theme, my dining table contributing to the project. Yes I live alone.

Busy busy busy. Lots of wiring and oratex the past few days.

Finished the radio/intercom harness. I'm confident that I did as high quality of work as any avionics shop. This picture is missing the rear headset jacks, those will get soldered on after the harness is routed through the airframe. Copilot PTT was taken off the yoke and will now be beside the copilot jacks since I usually have the copilot yoke out.



Panel pieces back from paint/powder and installed. Grey turned out a little lighter than I intended but I think it looks good.



Wiring the aux pump switches/lights on their little panel below transponder. Love this stuff.



Have been covering my control surfaces. Started with rudder and one elevator and have been pushing them through in unison. Will be ready for rib stitching tomorrow. Waiting on a part for the other elevator so will start on it in due time. I have a ton of pics of this process but just chose a few various ones. A couple show the same piece of oratex glued on (unshrunk), and then later once I shrunk it tight. Pretty cool stuff.





Second side of rudder glued and trimmed. Fabric puckers around edges from the heat of glue activation. I actually like this because it helps me know where I've achieved good temperature for glue activation.



Second side of rudder after shrinking with heat. Smooth smooth smooth.

looks great!

aaaaaand the wiring is done*. Everything in the panel is fully wired except things that need to go through the firewall. Those things are: mag switch, JPI probes, and alternator/starter circuits. All the wires going to wings are pulled as far as wing roots. Will be doing molex connectors there.

Here she is:


Hopefully it'll be nice for the next owner. Made sure everything had service loops, labels, and tried to route in understandable ways.





When I got that wiring done I threw in some interior panels I had made previously simply to switch it up. Since I had the rear pax headset jacks wired now, I could place my jack housing on the panel. These will get pulled out to get powdercoated down the road. Another shade off the grey scale I'm sure.



Leaving town for a couple weeks tomorrow so no updates for a bit.

Please keep the progress pics coming. I wish all Maules were built like you are building yours. Fun to watch it come together! Keep up the quality work.

Joe

twflyer wrote:Please keep the progress pics coming. I wish all Maules were built like you are building yours. Fun to watch it come together! Keep up the quality work.

Joe

Thanks for the kind words. After I posted that update I realized it would’ve been a good time for a before/after of the panel so here goes.

Looking great man. Want to come out to Oregon this winter to help me wire my new panel?

Zzz wrote:Looking great man. Want to come out to Oregon this winter to help me wire my new panel?

That is actually something I’d be interested in if I have time. No interest in troubleshooting old wiring but starting from scratch was very pleasant.

I love the way the switching and MCBs are all together, very sensible!!

Nothing satisfies quite like a well organised wiring system

What do you think of the cost of the oratex and quality? I have to do the Stabs and elevators and rudder on my plane and was wondering how much that would run compared to standard fabric. The rest of the fuselage will be open tube so wont have that cost at least.

I like oratex, it fits my situation. I don’t think it’s an end all be all solution though. The traditional fabric systems have their place. If you have experience/setup in traditional systems, they will be cheaper for sure. Oratex can save money/time because there’s no paint to buy to apply. If you’re starting from nothing in terms of experience and tools/supplies, likely oratex will be cheaper or at least the same in the end, but the materials are more expensive by a lot.

Back from my trip and back at it. Finished the rib stitching and tapes over the stitching on the right elevator and rudder. Waiting on a part before I can cover left elevator.





Started making moves towards mounting the firewall and engine now that everything behind the panel is done. Installed JPI CHT probes and oil temp. Started on EGT but ran into a slight dilemma. There was 1 EGT probe installed prior to this. The hole is at a suitable location except that on 2 of the 6 exhaust stacks, there is a slip joint in that location. So do I leave that probe in the original location and put the other 5 down further (0.5" further down) below the slip joint? Do I get that hole welded and then put them all at the same distance from cylinder, below the slip joints? Figure I'll call JPI and ask.

Weld the hole and mount them all in uniform locations.

Kurt

G44 wrote:Weld the hole and mount them all in uniform locations.

Kurt

+1.

I say weld the hole. I would be interested to know what JPI says. I wonder how much it would change your reading if you don’t weld it?

Thanks for the input, it actually helps. Likely will go ahead and drill the other 5 in the "right" location and then wait to drill that 6th one until I can get the first hole welded, even if that's after the airplane is together.

Have been hard at work everyday, haven't had much time for posting.

After lots of work getting the firewall and baffles up to snuff, I now have he engine on the plane. All engine controls are hooked up and operational. All firewall passthrough/penetrations are done and in place. Wiring aft of firewall is complete, forward of firewall I still have to add the connectors to the JPI transducers but all the transducers are in place and mounted. Got all the hoses built for transducers. With a vacuum system gone and my alternator controller taking the place of 3 original boxes, the firewal is much simpler now. Of course the EDM900 adds a billion wires to keep it interestin. Did a little work on some interior panels when I got bored, and also have the rudder mounted and rigged. Aileron loop cable is tensioned and ready to add the rudder tab interconnect cable. Pitot & static lines (went with push-to-connect style) are ran to instruments. Carpet and glareshield cover material ordered from SCS! Went with featherweight carpet not so much for the weight savings but also the price and color options. Weight savings is a bonus too. I like carpet over slick floors in fabric-bellied planes to keep stuff out of the belly. I'm sure I've done a bunch of stuff I've forgotten.

Moving along. Pics from various steps. Engine is about 800 hr engine, good shape but dirty.

Onward. Billions of tiny sub-projects. A lot of time has been spent getting firewall forward how I want it, wiring transducers and such. Still haven't mounted the EGT probes but otherwise the probes are done.

Wanted to do something a bit different today so I knocked out the floorboards, carpet, and a couple more interior panels. Was able to re-use all the old floorboards with small improvements. Featherweight carpet from SCS is exactly what I was looking for and super lightweight - surprisingly so when you pick it up.

These pictures are how it sits right now.