14 Oct 2012
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The project is fast approaching 2 years since when we first started and some 1255 man hours later (and 9000 rivets) we have something that looks like an aircraft.With the VMFG allowing us to use some space in their workshop, it has enabled us to move very quickly ahead.
The majority of the airframe fabrication and assembly work is now completed except for some wing fairings etc.
We have been going over all the bolts making sure everything is installed correctly and nuts in safety.
The electrical system is also basically completed with everything working as advertised.
There maybe one or two items to overcome such as where certain items are installed being too close to control cables or other wiring.
Minor details which are all being looked at. Mal has done a great job in designing safety features in the electrical system in our Hornet.
This includes a redundant power system which will automatically take over if the main one fails.
The fuel system is still to complete and this includes the fuel vent line installation for the header tank.
I am having assembly issues with some fuel line fittings at the moment which is pissing me off actually… Mal and I hope to carry out some testing of the fuel system.
We will do this by teeing in a test gauge to measure the performance of the fuel pressure regulator on the engine with one pump running and then both.
It is normal in these auto engine conversions to have both pumps running for take-off and then turn one off for cruise.
I felt that this would be too much for the tug pilot to worry about and we are looking at system which requires no input from the pilot.
Peter has done some great work on the exhaust system. It has at times proved to be troublesome trying to get it to fit the way Peter intended.
Currently we are happy where it is at but it could be that some rework of this system is required. So at the moment we are seeing how it works initially.
Chris Trewern has continued to show us all his skills with some great work on some custom air outlet fairings on the engine cowl.
Chris also spent some time redesigning some air vent outlets to give better clearance on some wiring. Great work Chris.
When we assembled the Hornet for the dinner for everyone to look over, we discovered the engine cowl maybe a little too close to the Propeller.
I feel there may not be enough room for the blades to be adjusted to the different angles required.
A rework of the engine cowl by trimming 10-20 mm off the firewall end could be the fix. Further investigation is required.
Basically we are all working towards testing the engine very soon.
Also I will be looking to do the aircraft weigh and Joe Luciani has offered to help us (Joe has a set of scales).
Joe has kindly arranged the stencils to be made in order to paint the rego letters on the airframe.
On the paperwork side, our Hornet is registered (VH-OHT, Our Hornet Tug…..) and the club is the approved Operator just like the gliders.
The noise exemption Certificate is another piece of paper which is necessary and was issued by AirServices Australia.
Steve Jinks has done some great work on the insurance side and we hope to have this sorted soon.
I spoke with Ole this week and he has an engineer working on some load calculations on how much the Hornet can take.
His initial work indicates that it should handle a glider up 750kgs easily. Ole is hopeful that this work will be completed soon.
He is still making plans to fly down for the first flight.
Finally it was great to the Hornet come together very quickly, my thanks extends to Peter, Gordon, Mike and Mal for the many hours they have put in the last two months.
So overall we are going well and hope to get the engine running soon.
All for now, regards Jack
- Man hours to date:
- 1255hrs
