Powerplant
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Engine Sensor Installation
Installed rubber baffle material onto oil cooler duct. Installed EGT and CHT sensors onto engine and completed FWF wiring harness routing (other than oil pan heater). Verified temp probe operation with SkyView system then secured wires and routing in engine compartment. Secured throttle and mixture cables to engine mount using Adel clamps and started mapping…
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Engine Baffles – Part 2
Installed rubber baffle sections onto engine cylinder baffles with AAP rivets. Test fit baffles back onto engine and checked clearances. Installed spark plug wire grommets onto spark plug harnesses. Hours Worked: 2.27
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Cowl Fitment – Part 5
Continued to trim upper cowl to reach alignment with lower cowl. Removed lower cowl to clearance prop opening a little more. Used the bandfile belt sander for the last few passes which resulted in a slightly cleaner edge on the backside of the upper cowl. Once fit was close, reinstalled prop alignment hub and secured…
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Cowl Fitment – Part 4
Began fitting upper cowl by placing onto lower cowl and notating baffling interference. Trimmed front of baffles by about half an inch and rechecked clearances. Made the determination that tucking upper cowl under the windshield skirt will likely make removing the upper cowl difficult with prop in place. Began process of making a shelf for…
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Cowl Fitment – Part 3
Aligned the cowl into its final place then pilot drilled side hinges to cowl. Initially only pilot drilled a few holes due to space constraints. Pilot drilled a few holes in the bottom cowl hinge half by using flashlight method to locate holes through the fiberglass. Removed cowl and hinges from the airframe then finished…
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Cowl Fitment – Part 2
Decided to solve oil cooler clearance issue by moving oil cooler up by about 5/8″. Removed oil cooler bracket from bottom of engine and remade bracket from 1.5″ x 1.5″ aluminum angle stock with shorter leg. Installed new bracket on bottom of engine with Loctite 242 then reinstalled oil cooler to new bracket. Reinstalled lower…
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Cowl Fitment – Part 1
Began fitment of lower cowl by marking out locations for gear legs and fuel drain. Slid lower cowl into place and measured front face of cowl offset by approximately 1″. Trimmed back edges of cowl 1/2″ at a time while moving cutouts forward at the same time. Refit cowl and determined that proper forward alignment…
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Engine Baffles – Part 1
Crimped new 4 gauge starter cable onto cut portion with heat sink. Installed starter motor onto engine and ran cable down the oil breather line to starter solenoid. Briefly checked starter function. Created 4 intercylinder baffle plates based on forum recommendations and hung them underneath cylinders with safety wire and welding rod. Assembled right and…
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Oil Cooler and Separator Installation
Mounted oil cooler bracket onto bottom side of intake and secured bolts with Loctite 242. Temporarily mounted oil cooler to engine then marked areas of baffling to remove for block heater and oil drain. Installed AN fittings into top of oil cooler. Made oil cooler hoses and routed them from oil filter housing to oil…
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Mixture Cable Install
Installed mixture cable into center panel section and routed cable through previously installed cable safe. Measured out approximate length and removed inner cable from jacket (making sure to carefully catch ball in cable mechanism). Trimmed outer jacket then upsized cable hole in AeroInjector to 1/4″. Installed AeroInjector back onto back side of motor and ran…
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Throttle Bell Crank – Part 2
Installed throttle cable in center panel area. Located throttle and mixture cable pass-through locations on firewall and prepared holes for cable bulkheads. Installed both cable safes. Located throttle bellcrank assembly based on throttle cable pass through then transferred mounting holes onto firewall. Cleaned up bellcrank assembly then riveted pieces together and to firewall. Tested cable…
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Throttle Bell Crank – Part 1
Because we are planning to use a traditional push-pull throttle (instead of a Sonex throttle quadrant) with the AeroInjector, we needed a way to reverse the throttle direction. Assembled throttle bell crank and created mounting bracket from scrap 2″ and 1″ aluminum angle. Cannibalized cable parts from spare Sonex throttle components. Will need to final…