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Zenith CruZer & Sonex Logs
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Date: 1-21-2011
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Number of Hours: 2.50
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Manual Reference: aerovee
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Brief Description: Ground wires, oil cooler baffle, battery wires
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Lots of little piddly things today, but I felt productive.
The magnetrons must be grounded to the engine block. One way to do this is to attach the ground wire to one of the rivet-like studs on each magnetron. Unfortunately, these studs are 5/16, so a normal wire terminal (.25") will not fit. I tried for over a week to find a source for these wider terminals, but found none in quantities less than 100 (and I needed 2). Finally, Sonex said to just spread a standard terminal - hey - it works! Lots of trial and error fitting to get the spread just right where it wouldn't try to spring off after installing. Made up ground assy's for upper and lower magnetrons.
Up-drilled some of my 4-ga wire terminals to accept 5/16" bolts - I only ordered 1/4" hole terminals, but there was plenty of material remaining, so no issue. I also need some with 7/16" holes, since ground connections must be made to the starter mounting bolts. These could not be drilled to 7/16", since there won't be enough material remaining, so I ordered new ones.
Cut battery cables to length for battery to starter, starter to ground, starter to block, etc. - THEN I noticed that I overlooked the fact that I have a master relay, so one piece is too short. Fortunately I have some remaining cable, so I'll be OK.
Lastly, the new lower oil cooler baffle arrived today from Sonex, so I bent that into the correct shape.
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Magnetron ground wire
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New baffle bent correctly this time
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