Tue Sep 30 17:08:31 2008 - Perfect fit.

Tue Sep 30 17:05:54 2008 - And voila!

Tue Sep 30 17:03:12 2008 - It just so happens that the fly-cutter will adjust down to the proper size for the pass-through hardware - barely. The problem now is how to keep a small piece of stainless fixed in place while a big chunk of metal is spinning around. Answer: Affix it to a 12" piece of 2x4.

Tue Sep 30 17:02:14 2008 - Ok, this has been bothering me for some time. This was the first hole I punched using an honest-to-goodness Green Lee punch set. During the process, it snagged and tore the stainless. Even with the pass-through installed, there was still a hole that CO could enter the cabin. Also, I wasn't too keen on applying some RTV/proseal to cover the hole. So, today I decided that I was going to remedy this by using the remains of heater valve cut-out.

Tue Sep 30 16:37:35 2008

Tue Sep 30 16:37:04 2008 - With the high temps around here, I opted to go with a 1st class oil cooler (a Stewart Warner 8406R from Pacific Oil Cooler Service) rather than the standard Van's model. Comes with a lot of paper work.

Sun Sep 28 13:37:59 2008 - Decided it was time to attach the heater valve. The big hole was cut with a fly-cutter using a cordless drill on the "slow RPM, high torque" setting. This was pretty painless. After that, I carefully measured the hole to the left and drilled that. Next I back threaded an AN3 bolt that I had ground down to a point (pictured) so that it just protruded on the other side of the heater valved. I then positioned the valve, installed one bolt, lined up the big hole, then marked the second hole by pushing. This left a nice perfectly positioned punch mark.

Sun Jun 1 19:33:09 2008 - Fitted the firewall penetrations for the throttle and mixture according to the locations on the plans. Also fitted and sealed the firewall recess. I've yet to drill the 2" hole for the cabin heat - but the position is marked. I also determined that I can not use the doubler plate originally intended for the carburetor electric fuel pump for the fuel injection penetration. It just so happens that the engine mount is in the way. Sure am glad I checked before drilling holes! On a separate note, I ordered the firewall forward kit this past Friday. I marked off some items that I either already had, or was going to source from a different vendor. In particular, I excluded the alternator, exhaust, battery tray, contactors/relays, wiring harness, and some other misc items. Van's called later in the evening to let me know that I had submitted an old order form and that the wiring harness was no longer included anyways. Also, they were now supplying the 60A Plane Power alternator as part of the FWF kit which is what I had planned to use anyways. So I added it back to the order. NICE customer service. Thanks, Van's!

Sun Jun 1 19:32:45 2008

Sun May 25 16:54:29 2008 - So I've been reading and hearing about this tool called the "Drill Doctor". Depending on the model, it'll sharpen your drill bits to 118 deg, 135 deg, variations of those, split-point, masonry bits. It's been in the back of my mind to get one but the price for the "pro model" was just south of $200 - until recently! Sears had them on sale for $140 so I got one. This thing is slick! In no time I had a number of bits sharpened and ready to go.