Category: Upgrades

With the next few steps in the plans having me rivet down the rear floor and seat panels, I realized that now was the time to install the Air Conditioner scoop. The kit for the AirFlow systems includes riv-nuts, however I have heard enough complaints regarding riv-nuts that I decided that since I have access I’m going to just install nutplates.

The first step is to mark the center line of the air scoop as well as the center line of the aircraft as you really want this to be perfectly centered. I spend a lot of time making a lot of measurements to try to make sure I get this correct. I’ll just say that the reflections from the skin and how I have my project sitting in my garage really did make this a difficult task as what I was seeing vs what my measurements were telling me did not agree.

I used making tape on the fuselage, a cardboard template I created from the scoop itself, as well as installing masking tape from down the length of the scoop to help me mark the centerline. I finally got to the point where I had to make the first hole in the skin. With the scoop clecoed to the skin, I drilled all screw holes and avoided drilling any of the spars.

Only after I did this did I read that someone used a sheet of acrylic to template the scoop so they could see where they were drilling. That was very smart and I wish I thought of it. Something to remember in the future I guess.

With all of the holes drilled, I used my nutplate jig to drill all the #40 holes for the nutplates. I then had to enlist my daughters to help me dimple the holes using the close quaters dimple tool. This is the dimple set that has a hole in the center and copper rods and nails to set the dimple.

Pro-tip: I found that the Stainless Finishing nails from Home depot were perfect vs the nails included in the tool. I ended up ruining a set when I pulled a nail though the dimple dies and had to get a replacement set.

With all the holes dimpled, I had my wife assist with back riveting the nutplates. After installing the scoop to make sure everything looked good, I needed to drill the holes for the radiator (condenser) into the center tunnel. This made a template and drilled the holes into the center tunnel. The instructions don’t tell you that you need to put a doubler around these holes, but I’m thinking that installing one may be a good idea. It’s on my list of things to do “later”

With the scoop installed, I putting the AC stuff off to the side until I get the baggage bulkhead installed At least I can store the scoop on the bottom of the plane for now so it’s out of my way.

Well, not how I really planned for things to go based on my last post regarding an AC system. Let me first say that this summer was hot. Hotter than normal and for the few flights I did end up taking, and it was fairly miserable when we were taxing and down low.

One of the big things I’m trying to keep in mind is the comfort of my family. I don’t mind getting a little sweaty as I try to climb to cooler weather, however once my wife and girls start feeling hot and uncomfortable, the will absolutely decide that they don’t want to go flying with me. OR they will only go flying when the weather “perfect”. Not a great situation to be in.

So with this in mind, I did more research, reached out to who I consider the two major vendors of A/C systems, and started to plan how I would proceed. After a lot of consideration, I have decided to purchase the system from Airflow Systems. This is a belt-driven system with an air-scoop on the bottom of the plane for the condenser. After a few conversations with Bill from AirFlow Systems, I decided that I would purchase the system now, while I’m still working on the fuselage and have full access to the floors to help plan cable routing.

Looking forward to getting the AC kit so I can get a better idea of installation, hose routing, and other items. I know there are lots of good blog posts out the and photos from others, but sometimes having the items in hand make it easier for me to fully understand how it all goes together.

So I have been going back and forth on this topic personally a lot over the last year or so. Initially I was of the opinion that this was a MUST for me for the comfort of my family. This has lead me to reading a number of blog entries from other builders on how they installed their systems and the different options out there.

Currently I’m following three systems (or two depending on how you look at it). Air-Flow systems, Flightline AC, and South Florida Sport Aviation (repackaged Air-Flow systems with overhead console). The Air-Flow / SF Sport Aviation system uses a condenser scoop that sits on the belly of the aircraft that looks like a P-51 scoop, while the Flightline system is contained in the tailcone just behind the baggage bulkhead.

I was personally thinking of going with the Air-Flow system package as I liked the idea of the condenser sitting outside of the aircraft. It looked slick and installation didn’t seem to be too challenging. It also didn’t have the issues of routing air for the condenser through the tailcone and freed up some space in the tail.

The downsides to all of this is that the AC is really only there to help on the ground, or down low on a really hot day. As I said I thought this was a MUST for my family, but starting to change my mind. In addition to it’s limited benefit, it is a complex system in general, with modifications needed Firewall forward, as well as in the fuselage. Extra hoses / cables that need to be routed, and additional weight to an aircraft. It is also an additional cost in time and budget.

As I submit my final payment for my fuselage and feel my bank account lighten, I am starting to plan out some of the additional items that I will need to order throughout the year for this project. Since an A/C is much easier to install when working on the fuse, this item is highly visible on my list of things that may need a decision in the near future. At the moment, I’m of the opinion that an AC is a luxury item that is not needed in my situation. With the exception of possibly going to Oshkosh, I shouldn’t be in a position where I will have an extended ground taxi in extreme heat / sun.