Powerplant
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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…
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Engine Installation – Part 1
Continued working on Sonex FWF manual for the Jabiru by marking and trimming cooling fins on cylinder #1. In lieu of further trimming cylinder fins to fit spark plug CHT ring sensors, will opt to use #8 ring terminal sensors for easier access. Removed existing baffling from front of engine and old oil cooler. Measured…
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Thrust Line Measurement
Verified engine alignment before moving forward by leveling fuselage with saw horse under tail and setting up laser level though center of crank. Measured bottom front corner of fuselage at 22.75″ from floor and center of crank as 40.25″ from floor leaving 17.5″ from thrust line to bottom of fuselage; right on spec.
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Firewall Forward Fuel System
Began working on firewall-forward fuel system by bending solid fuel line for drain branch. Ran -6 fuel line behind upper part of engine mount then bent line to come forward of bottom part. Created a drain cock mount out of scrap aluminum angle and secured drain cock and mount to engine mount with Adel clamps.…
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Engine Hardware Replacement
Replaced temporary engine mount hardware (too long) with properly sized AN4-46A bolts and AN363 nuts.
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Initial Engine Mounting
Began process of mounting engine to determine firewall location of other items by using engine hoist to lift engine off of table and onto airframe. Placed ACV-J01-10 engine shock mounts onto engine mount then maneuvered engine onto airframe. Used bolt guides that came with engine to secure engine to airframe. Measurements for the AN4-51 bolts…
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Battery Box – Take 2
Second attempt at making battery box by recutting out template from 0.032 sheet stock and bending with bench bender. Deviated from plans design by omitting LH side panel to be replaced with hinged panel for side removal of battery. Cut various lengths of -3 piano hinge and riveted hinge halves to battery box using flush…
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Battery Box – Take 1
Measured out ETX900 battery to make flat sheet template for cutting battery box. Added 1/4″ to depth to account for edge of piano hinge on LH side. Drilled corner relief holes and mounting rivet holes then cut flat template with Andy snips. Bent flat sheet with bench brake then realized bends were going wrong direction…
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Follow-up Storage Treatment #4
Performed long-term storage procedure IAW Jabiru Maintenance Manual. Removed plugs and lubricated cylinders with Phillips 20W50 Anti-Rust Oil. Reinstalled plugs but did not torque. Removed rocker covers and lubricated rocker chambers with same oil. Reinstalled rocker covers but did not torque. Pulled prop through 15 times. Hours Worked: 0.58
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Follow-up Storage Treatment #3
Performed long-term storage procedure IAW Jabiru Maintenance Manual. Removed plugs and lubricated cylinders with Phillips 20W50 Anti-Rust Oil. Reinstalled plugs but did not torque. Removed rocker covers and lubricated rocker chambers with same oil. Reinstalled rocker covers but did not torque. Pulled prop through 15 times. Hours Worked: 0.63
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Fuel System Plumbing – Part 3
Installed 45 degree and AN fitting after fuel cube using Teflon paste. Cut a piece of solid aluminum fuel line to length and used tubing bender to bend into shape. Installed tube nut hardware on hardline and used flaring tool to flare ends of hardline. Installed hardline in between fuel flow cube and bulkhead fitting.…