47 - Cowl Baffle (finished); 50 - Control Cables (prop cable); 51 - FWF Misc. (route mag harnesses); Avionics (FWF wire terminations)

A lot of miscellaneous tasks were accomplished during the past couple of weeks, the most noticeable of which was wiring the various FWF sensors to the avionics, as well as finishing the damned cowl baffle. They both are looking good though.  Oh, and I had a visit from my buddy, Ken B., who gave me an initial Pope's blessing for the FWF - before we do the first engine run-ups, he'll go over everything with a fine-toothed comb.  For now, most everything was good, and a couple things were fixed.  Specifics for the past week are listed below:

- attached magneto/emag cooling tubes; sealed baffles with lots of red RTV

- formed and attached clamping strips to bottom cowl air inlets; epoxy-floxed between cowl and strips

- sanded bottom cowl outboard and inboard air inlets to curve to match the baffle’s width; added epoxy/flox to top cowl to eventually sand down to match bottom cowl (outboard edges of air inlets)

- sanded top and bottom cowl outboard inlets to match each other; attached inlet seals (except one screw - need a longer screw); attached foam block to top cowl with red RTV; mostly done with the cowl baffle section!

- installed prop bracket & cable; partially attached sniffle valve and tubes/hoses; ; finished installing alt. air cable

- Route, adel-clamp, and attach spark plug harnesses (from Slick magneto and P-mag)

- Ken B. visited to check out my FWF and avionics install to date - great to catch up, and I appreciated the advice!

- installed CHT and EGT probes; messed with routing wiring for EGT and CHT (K-type wires); inventoried misc. hardware and supplies that I bought from Ken. B.

- worked on wiring under panel; routed and wired CHT and EGT probes

- wired a couple FWF sensors (fuel pressure, oil pressure)

- wired master solenoid, starter solenoid, oil pressure switch, oil temp, main amp shunt (primary alternator), aux amp shunt (backup alternator), started tidying all wire bundles FWF

Using binder clips to pre-bend the stuff rubber seals:

Attached lower cowl to determine distance from aft edge of inlet to air filter bracket (determines how much to flox/sand):

Same, for the right side inlet:

Floxing lower cowl inlets with seal brackets temporarily attached:

Other side:

Sanded and rounded outer edges to match contour leading into the baffle inlets: 

Attached top and bottom cowl to see overlap of top inlets, which will need to be floxed and sanded to match lower inlets:

Closeup, showing area that needs to be floxed and sanded on top cowl:

Other side:

Bottom cowl, with inlet seals in place:

Top cowl, attached to fuselage, to check fit:

Added last heat duct scat tube to air inlet baffle on right side:

Attached prop governor bracket and prop cable:

Used closed-cell foam to seal contour around governor:

Attached alternate air inlet cable - FAA, please notice my pic in the reflection!

Starting to wire the EGT and CHT probes:

Another view, showing probes attached to engine, but not yet wired to the avionics:

A view of the right side EGT/CHT wires, routed nicely:

Another view, from the aft right side:

Right side, fully wired (magneto harnesses also routed and attached to spark plugs):

Left side EGT/CHT, routed:

A mess of wires, but this shows the EGT and CHT wires routed (the mess gets cleaned up slowly over the next few pics):

Using a solder sleeve to attach a ground to the shielding:

Wired fuel flow transducer:

Wired oil pressure gauge, oil pressure switch (turns on Hobbs meter), and fuel pressure gauge:

Magneto, wired (I could have done a better job by using heat-shrink tubing - I might redo, or I might leave it alone.  It isn't critical to shrink wrap the wires for a little extra stability ... but it is best practice to do so):

Wired ammeter shunts for the primary (top) and secondary (bottom) alternators.  Note that each wire gets a 1A blade fuse in an inline holder - incase of a short, you don't want 60 amps frying the avionics: