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181 Receives Planned Upgrades

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Area-51

Joined: 03 May 2021
Posts: 391

Posted: Mon Dec 25, 2023 10:26 pm Post subject: 181 Receives Planned Upgrades

Wow what an epic journey this one has been. After months of developing solutions and some failures along the way 181 has finally received its planned upgrades, entering a new level of fit for purpose.



Second AV-30 now fitted offering separate AH and DG appointment, completing the full traditional Six Pack. Also fitted Uavionix TailbeaconX ADSB Mode S ES transponder, Uavionix AVMAG magnetometer paralleled to both AV30's, Davtron OAT thermocouple sensor coupled to DG unit providing TAS DALT,  NMEA GPS Flight Plan data integration paralleled to both AV30's from Garmin Pilot III. AV30E latest firmware loaded to DG unit offering full flight plan graphical waypoint display. 30W 6chip LED landing/flight lights fitted at each outrigger station, new improved 3D printed outrigger speed kit cowlings fitted. Panel wiring cleaned up. New laser cut instrument panels fitted. New 3D printed GPS Pilot III mounting fitted. New trial 3D printed panel tags added.



It was epic. Lot's of stuff failed; even after successful bench testing. But quality assurance checks at various points identified faults and prevented catastrophe down the line.



The Garmin GTX327 originally selected worked great. The 2nd hand altitude encoder did not. After wasting hours setting up bench testing rigs it was decided more time efficient to just go out and order a new transponder. TailbeaconX proved a challenge on mounting it somewhere that did not look out of place. The middle flap horn cowling was selected. After ten failed 3D printed TBX mountings the eleventh passed all the requirements. The outrigger cowling took nine attempts to get right after finding left and right side factory cowlings are not symmetrical. That was solved with new fixing holes being drilled and the overal cowling width increased by 5.0mm for hassle free fitting and removal. Wiring was routed from the wing root cavity out along the flap cavity to both outriggers and secured with polyurethane. The 3D printed BeaconX housing was flow tested and returned 72g of excess drag at 100kt.



Initial post bench test quality control of the panel wiring after fitting to the AC failed. Upon pulling the gyro fuses to save battery power faint sizzling was heard behind the main instrument panel. No guesses what the cause was going to be. One of the crap D-Sub connectors was experiencing high resistance voltage tracking (a high risk of panel fire existed at this point); they are a real shit connector solution and not even true milspec; a really disgraceful blight on modern aviation and I have no idea why they are still employed... So after ripping out both D-subs a whole day was spent making up two new connectors with much higher quality components and patching them in. (Fire risk failed connector cut open inspected confirmed and thrown into the bin where it and all others like it belong)... With everything now functioning as required a final load test was performed on the electrical system; 6.8A all aircraft electrical items functioning simultaneously.



Why use the Garmin Pilot III, its so out dated? GPS NMEA data protocol has not changed over the years, only the screen graphical display has. The Pilot III provides a horizontal vertical track guidance bar which can be used similar to ILS; a nice option to have allowing arrival at waypoint altitudes at desired rates of climb or descent and only seen now on very expensive units. Eventually this will assist in driving and monitoring an AP solution.



After nearly three weeks of solid unrelenting work and 12 hour days the lights finally went on at 10.30 last night; ready for op's. Waiting for ICAO Mode S  HEX code to be allocated before flight testing. Post testing items required before op's; supplement current AV30 and Flight Light inline fuses with dedicated panel mounted fuse holders.



That's all for now, wishing all a good and prosperous year!

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Looks great; can't wait for the storms to pass and go fly the 181 sky machine

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Thats a wrap; box it up Billy

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Two replacement quality D-Sub ancient outdated redundant "why are we still even using this outdated crap" connectors ready to patch in.

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Bench testing the Garmin Pilot III NMEA data interface with the AV-30

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Aero testing the BeaconX mounting in the digital wind tunnel. Its too expensive an item to loose in flight to just slap on and hope for the best.

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They are now fully symmetrical precision cowlings and only 80g heavier than factory

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It was not that simple to fit; but it all came together with persistence and determination

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Very bright, 6 5W 6500k cree chips per lamp. 2.4A per side.

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Last edited by Area-51 on Tue Dec 26, 2023 5:08 am; edited 1 time in total

peterz(at)zutrasoft.com
Guest

Posted: Tue Dec 26, 2023 3:19 am Post subject: 181 Receives Planned Upgrades

Neat, and congrats!



Curious why you didn't simply mount the tail-beacon inside the fuse, turning off the light?



Cheers,

PeteZ



 	  Quote: 	
		   On Dec 26, 2023, at 1:32 AM, Area-51 <goldsteinindustrial(at)gmail.com> wrote:

 

 

 

 Wow what an epic journey this one has been. After months of developing solutions and some failures along the way 181 has finally received its planned upgrades, entering a new level of fit for purpose.

 

 Second AV-30 now fitted offering separate AH and DG appointment, completing the full traditional Six Pack. Also fitted Uavionix TailbeaconX ADSB Mode S ES transponder, Uavionix AVMAG magnetometer paralleled to both AV30's, Davtron OAT thermocouple sensor coupled to DG unit providing TAS DALT,  NMEA GPS Flight Plan data integration paralleled to both AV30's from Garmin Pilot III. AV30E latest firmware loaded to DG unit offering full flight plan graphical waypoint display. 30W 6chip LED landing/flight lights fitted at each outrigger station, new improved 3D printed outrigger speed kit cowlings fitted. Panel wiring cleaned up. New laser cut instrument panels fitted. New 3D printed GPS Pilot III mounting fitted. New trial 3D printed panel tags added.

 

 It was epic. Lot's of stuff failed; even after successful bench testing. But quality assurance checks at various points identified faults and prevented catastrophe down the line.

 

 The Garmin GTX327 originally selected worked great. The 2nd hand altitude encoder did not. After wasting hours setting up bench testing rigs it was decided more time efficient to just go out and order a new transponder. TailbeaconX proved a challenge on mounting it domewhere that did not look out of place. The middle flap horn cowling was selected. After ten failed 3D printed TBX mountings the eleventh passed all the requirements. The outrigger cowling took nine attempts to get right after finding left and right side factory cowlings are not symmetrical. That was solved with new fixing holes being drilled and the overal cowling width increased by 5.0mm for hassle free fitting and removal. Wiring was routed from the wing root cavity out along the flap cavity to both outriggers and secured with polyurethane. The 3D printed BeaconX housing was flow tested and returned 72g of excess drag.

 

 Initial post bench test quality control of the panel wiring after fitting to the AC failed. Upon pulling the gyro fuses to save battery power faint sizzling was heard behind the main instrument panel. No guesses what the cause was going to be. One of the shit D-Sub connectors was experiencing high resistance voltage tracking (a high risk of panel fire existed at this point); they are a real shit connector solution and not even true milspec; a really disgraceful blight on modern aviation and I have no idea why they are still employed... So after ripping out both D-subs a whole day was spent making up two new connectors with much higher quality components and patching them in. Fire risk cut open inspected confirmed and thrown into the bin where it and all others like it belong.

 

 Why use the Garmin Pilot III, its so out dated? GPS NMEA data protocol has not changed over the years, only the screen graphical display has. The Pilot III provides a horizontal vertical track guidance bar which can be used similar to ILS; a nice option to have allowing arrival at waypoint altitudes at desired rates of climb or descent and only seen now on very expensive units. Eventually this will assist in driving and monitoring an AP solution.

 

 After nearly three weeks of solid unrelenting work and 12 hour days the lights finally went on at 10.30 last night; ready for op's. Waiting for ICAO Mode S  HEX code to be allocated.

 

 That's all for now, wishing all a good and prosperous year!

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=512947#512947

 

 

 

 

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Area-51

Joined: 03 May 2021
Posts: 391

Posted: Tue Dec 26, 2023 4:58 am Post subject: Re: 181 Receives Planned Upgrades

Thanks... The tailbeacon position light is the transponder's power gateway. Turning off the light also turns off the transponder. Panel mounted switch to the right of the comms radio provides function override. And for the cost of the LED position light with free transponder attached it would not be good value if nobody could see the light inside the fuselage.🤓

peterz(at)zutrasoft.com
Guest

Posted: Tue Dec 26, 2023 5:14 am Post subject: 181 Receives Planned Upgrades

Fwiw, a local here did disable the light successfully.  



 	  Quote: 	
		   On Dec 26, 2023, at 8:05 AM, Area-51 <goldsteinindustrial(at)gmail.com> wrote:

 

 

 

 Thanks... The tailbeacon position light is the transponder's power gateway. Turning off the light also turns off the transponder. Panel mounted switch to the right of the comms radio provides function override. And for the cost of the LED position light with free transponder attached it would not be good value if nobody could see the light inside the fuselage.🤓

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=512949#512949

Area-51

Joined: 03 May 2021
Posts: 391

Posted: Tue Dec 26, 2023 1:15 pm Post subject: Re: 181 Receives Planned Upgrades

Correct, 978mhz Tailbeacon unit marketed in US has option to turn off position light in Wifi Settings gateway and has a transmit power of 25W. 



1090mhz TailbeaconX unit is not provided option to turn off position light in Wifi Settings gateway. TailbeaconX also faciliates WAAS and 250W of transmit power

peterz(at)zutrasoft.com
Guest

Posted: Tue Dec 26, 2023 1:39 pm Post subject: 181 Receives Planned Upgrades

It was the tailbeaconX, as part of their beta program here in Canada. He has it in his fiberglass rv wintip.



Cheers,

PeteZ



 	  Quote: 	
		   On Dec 26, 2023, at 4:21 PM, Area-51 <goldsteinindustrial(at)gmail.com> wrote:

 

 

 

 Correct, 978mhz Tailbeacon unit marketed in US has option to turn off position light in Wifi Settings gateway and has a transmit power of 25W.

 

 1090mhz TailbeaconX unit is not provided option to turn off position light in Wifi Settings gateway. TailbeaconX also faciliates WAAS and 250W of transmit power

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=512951#512951

Area-51

Joined: 03 May 2021
Posts: 391

Posted: Tue Dec 26, 2023 6:52 pm Post subject: Re: 181 Receives Planned Upgrades

Nice... its good to be a test pig sometimes; access to special developer features!



I didn't like the TBX anywhere on the europa's rudder. I tried it on the horizontal stab also and didn't like it there either due to the need to cable all the down to that position. Thought about laying it with the dipole on the horizontal but was informed by supplier it needs to be vertical orientated with gps chip facing upwards due to moisture drain hole position. Supplier also suggested it go inside the fuselage, but again I wanted to utilise the position light feature.

peterz(at)zutrasoft.com
Guest

Posted: Wed Dec 27, 2023 1:39 am Post subject: 181 Receives Planned Upgrades

Xcept he didnt tell them it was inside the fuse 



 	  Quote: 	
		   On Dec 26, 2023, at 9:58 PM, Area-51 <goldsteinindustrial(at)gmail.com> wrote:

 

 

 

 Nice... its good to be a test pig sometimes; access to special developer features!

 

 I didn't like the TBX anywhere on the europa's rudder. I tried it on the horizontal stab also and didn't like it there either due to the need to cable all the down to that position. Thought about laying it with the dipole on the horizontal but was informed by supplier it needs to be vertical orientated with gps chip facing upwards due to moisture drain hole position. Supplier also suggested it go inside the fuselage, but again I wanted to utilise the position light feature.

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=512955#512955

phillik747

Joined: 04 Apr 2012
Posts: 73
Location: Birminham, AL USA

Posted: Wed Dec 27, 2023 11:18 am Post subject: Re: 181 Receives Planned Upgrades

That is nice setup!  Are you willing to share those 3d files?



I have been on the fence with and av-30 setup, but it seems you have to be in the ecosystem for a working ads-b solution.  Your setup is impressive.



My main holdup on an AV-30 solution is working with what I already have. I wrote my own altitude encoder software that listens to pressure altitude given over wifi in NMEA format.  It then relays that in ICARUS format over RS232.  I have been wondering if I can utilize the signal coming from the AV-30 (using their AV-Link) and convert it. Or connect to it over rs232 to capture the data. That way I can use the AV-30 to update the pressure altitude on the GTX-327, via my script, and use the EchoUAT for ADS-B out/in.  This is all hypothetical since I dont have an AV-30 to test with. 



My script is on github:

https://github.com/icarus747/PicoICARUS





/Kyle

_________________
Kyle
Europa Tri-gear (under construction)

spcialeffects

Joined: 29 Aug 2012
Posts: 306
Location: Kent

Posted: Sun Dec 31, 2023 3:50 am Post subject: Re: 181 Receives Planned Upgrades

I see your landing lights. I to made some when mine was a mono

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rparigoris

Joined: 24 Nov 2009
Posts: 796

Posted: Sun Dec 31, 2023 12:47 pm Post subject: Re: 181 Receives Planned Upgrades

Hi Area 51 and Special Effects.



Did you aim both lights for Taxi? 



Both lights for Landing?



One aimed for Taxi and one for Landing?



Were you able to aim where the lights were useful? We were fooling a little with lights at that position and the aim is very critical and touchy.



Thx

Happy New Year to all!



Ron P.

Area-51

Joined: 03 May 2021
Posts: 391

Posted: Sun Dec 31, 2023 5:49 pm Post subject: Re: 181 Receives Planned Upgrades

[quote="spcialeffects"]I see your landing lights. I to made some when mine was a mono[/quote]



They look awesome; looks like fair bit of fine shaping... were you happy with the result?!



Weather sux here right now; spent weeks working right up to a deadline only to have nature say, NoGo, take the big plane 😂😂🤓🤷🏻‍♂️



Aiming? I just slapped them on, set level to cruise attitude. Will probably focus on and install strobe driver this week.



Won't be moving forward with CAD files until field testing process is complete; unknown yet whether the 3D prints will disintegrate in flight or what final amendments may be required.

Area-51

Joined: 03 May 2021
Posts: 391

Posted: Sun Dec 31, 2023 6:23 pm Post subject: Re: 181 Receives Planned Upgrades

[quote="phillik747"]That is nice setup!  Are you willing to share those 3d files?



I have been on the fence with and av-30 setup, but it seems you have to be in the ecosystem for a working ads-b solution.  Your setup is impressive.



My main holdup on an AV-30 solution is working with what I already have. I wrote my own altitude encoder software that listens to pressure altitude given over wifi in NMEA format.  It then relays that in ICARUS format over RS232.  I have been wondering if I can utilize the signal coming from the AV-30 (using their AV-Link) and convert it. Or connect to it over rs232 to capture the data. That way I can use the AV-30 to update the pressure altitude on the GTX-327, via my script, and use the EchoUAT for ADS-B out/in.  This is all hypothetical since I dont have an AV-30 to test with. 



My script is on github:

https://github.com/icarus747/PicoICARUS

[img]https://i.imgur.com/FKRuoDD.png[/img]



/Kyle[/quote]



Thanks Kyle - Will check the script out; i'm not a natural at code writing but can understand it after a lot of mumblings.



I can't speak highly enough about the AV-30 solution. However my assumption regarding ILS being added down the line was incorrect; hardware limitations will not allow this; which is why the PilotIII with its glide slope feature is being retained. Currently seeing if an RS232 sentence is allocated on this.



The Uavionix platform just works. Its hassle free integration makes installation  as easy as Instal Setting feature select and Calibration procedure performed either once inflight or preflight depending on feature set. At the moment firmware updates require instrument removal but the tales have been put in place to add an RS232 update port when required. One of the units totally died on a firmware upgrade (it was doing some minor weird stuff before the upgrade so maybe had some inherent issue); out of warranty and Uavionix sent out a brand new replacement straight away. The connector pins for me are the only let down; i would prefer to see a quality full closed tube crimp terminal rather than open roll over tab solution.



The GTX327 will not communicate directly with AV-30 for either I/O ALTITUDE data or SQUAWK. This was my original planned setup. It would require a translator box and i didn't need yet another project that might not work. That being said the GTX327 with ALT-ENCODER and ADSB out interface will work just fine. It won't work however with the GARMIN GAE12 digital encoder used on GTX330 TX. Some EFIS and EEMS solutions can supply Serial RS232 Altitude data via Ambient Inlet Manifold Pressure sensor to the GTX327 also.



Are dual AV-30 units required for DG / AH function? No, a single head unit will perform both functions and is hot swappable in flight. The Garmin G5 does not offer this, but you do get ILS functionality.

spcialeffects

Joined: 29 Aug 2012
Posts: 306
Location: Kent

Posted: Mon Jan 01, 2024 3:50 am Post subject: Re: 181 Receives Planned Upgrades

Mine were/are on brackets so can be positioned as required. I have recently converted to tri gear and so the fairings and lights are no longer fitted to my aircraft.

spcialeffects

Joined: 29 Aug 2012
Posts: 306
Location: Kent

Posted: Mon Jan 01, 2024 5:09 am Post subject: Re: 181 Receives Planned Upgrades

Mine were/are on brackets so can be positioned as required. I have recently converted to tri gear and so the fairings and lights are no longer fitted to my aircraft.

rparigoris

Joined: 24 Nov 2009
Posts: 796

Posted: Mon Jan 01, 2024 8:52 am Post subject: Re: 181 Receives Planned Upgrades

Hi Specialeffects



Did you have light/s adjusted for taxi or landing? Or were they primarily to be seen lights?



If they were adjusted for taxi or landing, did they work effective for task at night?



Thx.

Ron

spcialeffects

Joined: 29 Aug 2012
Posts: 306
Location: Kent

Posted: Tue Jan 02, 2024 3:32 am Post subject: Re: 181 Receives Planned Upgrades

I had them just to be seen but they can be adjusted to aim where you like. They are super long distance leds

drewbinsky

Joined: 20 Jun 2023
Posts: 2

Posted: Wed May 29, 2024 8:43 pm Post subject: Re: 181 Receives Planned Upgrades

What an incredible journey indeed! Completing Tunnel Rush such an ambitious project in just under three weeks is a testament to your skill and determination.

Area-51

Joined: 03 May 2021
Posts: 391

Posted: Thu May 30, 2024 1:39 am Post subject: Re: 181 Receives Planned Upgrades

How do we stop SPAM ruining our conversations?

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