Upgrades and improvements to PA-22-160 Tri Pacer 09-1130

Upgrades and improvements to PA-22-160 Tri Pacer
1. Aeroflash wingtip strobes.
Mounted to 61S-T (modern 6061-T3) extruded aluminum spars with (6) #6 machine screws and rivnuts. The power
supplies were mounted to the 2024 T3 .040” aluminum plates with (4) 10-32 machine screws, fiber lock nuts and AN960
washers. Installation centered exactly between the #11 and #12 ribs exactly 10’ from the inboard face of the butt rib.
Individual power supply weight- 1.31 pounds. Strobe light mounted according to Aeroflash wingtip strobe light system
installation instructions.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
2. Vacuum instrument filter installation
AIRBORNE FAA-PMA P/N D9-14-5 Filter installed into holder, which is secured with two DG10 adel clamps to 4130
steel fuselage tubing using 10-32 machine screws, fiber lock nuts and AN960 washers.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
3. Starter solenoid mount
Installed properly rated battery relay in original starter relay location and mounted original starter relay on the
bottom of the Brake pedal guard behind the original box housing. Used (2 each) AN3 bolts, AN960 washers, and
lock nuts to mount solenoid on underside of aluminum “brake pedal guard”.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
4. Intercom installation
SPA-400 Sigtronics Intercom installed according to Sigtronics installation drawing in spare hole on right side of
instrument panel.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
5. Left landing gear “kick panel”
Fabricated from .032” 2024 T3 aluminum panel
and bent to fit around leading and trailing edges of
gear leg. Installed by fitting over step then sliding
up on gear leg and held up and tight by 4 machine
screws into rivnuts (same screws originally used to
hold gear fairings in place). Step, screws and curving
around the edges of the gear leg prevent the panel
from coming off and/or drumming in flight. Purpose
of panel; to prevent damage to fabric and/or
bending of landing gear trailing edge aluminum
former(under fabric).
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
6. Radio filler panel
Fabricated painted filler plate around transponder, Nav/Com, and Hobbs meter made of .025” 2024 T3
aluminum installed with #6 rivnuts and cadmium plated screws.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
7. Aircraft headphone/hand mic and Co-pilot phone/mic jack holder
Installed aircraft headphone jack/ aircraft hand mic jack in fabricated holder below the center of the panel, and
co-pilot mic and phone jack installed in fabricated holder below the right side of the panel. Both fabricated
panels were made from 2024 T3 .032” aluminum and were installed below the panel by #6 machine screws and
lock nuts.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
8. Ground buss bar
Installed MS25226-10-4 buss bar board assembly below the rear of the radio rack for central ground location
using two DG10 adel clamps to 4130 steel fuselage tubing. Grounded with AN6 copper wire to frame at firewall.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
9. Speaker/phone switch
Installed speaker-phone switch as per page 2-3 of the KX170B manual P/N 006-0085-01. Resistor also installed
as required by KX170B manual P/N 006-0085-01 for when speaker is not in use, as shown in figure 2-11 on page
2-19 of the same manual.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
10. Hobbs meter and oil pressure sensor installation
Installed pressure switch in oil pressure line 6” behind oil pressure gage and secured with adel clamp to the
frame and electrical connections using Piper dwg. 2I13 as supporting data for installation from PA-28 service and
maintenance manual P/N 761-539.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
11. Anti-drumming wing panel and inspection covers for left & right wings
.020” 2024 T3 32”x 11” aluminum panels used to fabricate an anti-drumming panel under the fabric. Panel
secured to
ribs using
existing
hardware.
Two 5”x 5”
inspection
holes were
cut out,
centered
between
the #1-#2
and #2-#3
ribs for
inspection
access.
1/8” rivets
were used to secure rings around the holes for flush-mounted covers. 8 F5000-08 floating nut plates were
riveted on with flush 3/32” rivets for securing the inspection covers with MS24693-S48 machine screws.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
12.
Radio tray installations
A.
KX175B Nav/Com radio tray, TSO# C37b and C38b, installed with existing vertical angles provided by
aircraft manufacturer in the panel center position . Installed I/A/W KX175B installation manual P/N 0060085-01 Revision 1 January 1976 for proper mounting technique.
B.
NARCO AT150 TSO Transponder installed on top position using the existing vertical angles provided by
aircraft manufacturer in the panel center position I/A/W Narco installation manual 03606-620.
C.
Narco AR-500 altitude reporter installed I/A/W manual 03725-0600, dated Aug. 1975. Mounted
horizontally on aluminum panel supplied by aircraft manufacturer for equipment mounting, on cockpit side of
firewall.
Radio tray rests on wooden
block secured to 4130 fuselage
tubing by DG10 adel clamps on
each end.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
13. Stainless steel door jam fabric protectors
.018” stainless steel with a 2B finish was fabricated to fit around the bottom and part of the rear of the door jam
on the front door in order to protect the fabric upon passengers’ entry/exit.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
14. Push to talk switches
Installed two new Push-to-talk switches in the center panel area, one on each side of the throttle control.
(required drilling holes in panel)
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
15. Circuit breaker panel
Fabricated (additional to original piper panel) circuit breaker panel identically to the original Piper 9-breaker
panel in order to provide for (6) additional breaker openings using .032” 2024 T3. Mounted with #6 screws and
lock nuts to the instrument panel(the same method originally used to mount the Piper panel).
Also used to mount two MS27212 terminal boards below breakers for ease of electrical circuit installations.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
16. Avionics master switch
Installed Avionics master switch in instrument panel to the right of the throttle control by drilling a hole in the
panel in this location.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
17. Com antenna installation
Com antenna installed on center of top left wing root fairing cover exactly 12” aft of the datum (wing leading
edge to
center of
antenna)
with a
gasket and
appropriate
mounting
hardware
according to
Comtant
installation
instructions.
Reference
attached
drawings for
details.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
18. Wing rib repairs
Rib capstrip reinforcements installed with Cherry Max rivets used as a deviation from the approved AN455A3-4
rivets called for in Piper Service Memo No. 10.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
19. Fuel tank welding flanges
AN867-4 welding flanges TIG welded to replace corroded original tank drain fittings on underside of both wing
fuel tanks. Pressure tested to 1PSI for leak check on both tanks.
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
20. ELT installation
Ameri-King AK451 installed with DG cushion clamps to 4130 structural fuselage tubing at rear of fuselage
inspection hole. Aluminum plate .050” 2024 T3 fabricated approximately as shown installed with cushion
clamps; rear edge(left of picture) 10”, left hand edge (top of picture) --~13”, right rear edge(bottom left of
picture)—7”. Power supply will be moved to one side in order to accommodate ELT and mounted to aluminum
plate along with ELT unit. Remote control mounted on instrument panel above intercom.
Main unit: 1lb 14oz
Remote unit: 1.0oz
Whip antenna: .25lb
Coax cable assy.: 5oz
Aural Monitor: .3oz
Mounting tray: 4oz
09-1130-04
Revision #4
Upgrades and improvements to PA-22-160 Tri Pacer
bracket for
whip antenna
mount
Remote control unit to be mounted above intercom on instrument panel.
09-1130-04
Revision #4