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Matt Dralle's RV-8 Project
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Date: 11-1-2009
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Number of Hours: 1.00
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Manual Reference:
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Brief Description: Oxygen System - Pulse Demand Unit Install - Part 2
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After some considerable thought, I ended up using the Dremel tool and a cutoff wheel to rough-cut a rectangular hole in the side panel, and then carefully and slowing filing out the hole to form a perfect fit around the little lip of the top of the O2D2 unit. The fit is nearly perfect with the O2D2 slipping in from the bottom.
The mounting ears were another thing. Opening up the O2D2 voids the warranty, so I thought there had to be another way to add some mounting ears. Then I remembered those melt-in, 2-56 brass inserts I'd used on the rear LCD display and decided to give them a try. I fabricated two 90 degree bracket angles from some .063" angle, carefully notching them over the strap ears on the sides of the O2D2. I then marked and drilled two 3/32" holes in the brackets and then placed them on the O2D2 and match drilled into the plastic case, being careful not to drill too far past the thickness of the plastic. Turns out, there was nothing behind any of the screw holes I added. The brass insert on the soldering iron trick worked like a champ and I had four nice, threaded, mounting screws holes in the O2D2! Since all of the load will be shear on the brass inserts, they should be plenty strong for the application.
There were two pre-punched 3/32" holes in the fuselage bulkhead already, so I was kind of forced to use then as two of the screw holes. There wasn't enough room on the .063" angle bracket to add a platenut, so I just drilled and tapped the bracket for 6-32 screws. Since the bracket metal is pretty thin, I decided to add a couple of additional 6-32 platenuts just to be safe.
Cont. Next Log...
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EDS O2D2 Mounting - Fuselage Bulkhead Filed
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EDS O2D2 Mounting - Mounting Bracket Fabrication
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EDS O2D2 Mounting - Adding Melt-In Inserts
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Copyright © 2008-2024 Matt Dralle. All Rights Reserved.
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