Regulator / Cowling hinge pins

Finally got back out to the shop to work some on the 12. Replaced the banjo fitting with a fluid fitting as per plans. Torqued to 19 ft lbs. (25 NM).  I modified the grommet and then placed it. The regulator wires were then placed through it, the regulator installed, and the wires connected.

At this point I think it is a good spot to work on the cowling before I add more to the engine. I started by preparing the hinge pins as per plans. I will work on trimming the cowling at a later date.

Time: 1.25 hrs.

Fluid Fitting

Modified grommet

Rectifier regulator

Cowling hinge pins

Engine wiring / fuel lines

Lots of other projects to do today, but since it was my birthday my family "forced" me to work on my plane. Started with attaching the VA-216, gascolator, fuel return, and fuel pressure lines. I then worked on the wiring which included the ignition, oil pressure, CHT, oil temp, and starter wiring. The manifold pressure hose was placed. I also cut, bent, and installed the drain line.

Time: 4 hrs.

VA-216 fuel line installed

Gascolator hose

Fuel return line

Fuel pressure line

Ignition wiring

Oil pressure sensor harness

Right CHT wire

Left CHT

Oil Temp Wire

Manifold pressure hose

Fuel Drain line

Fuel Drain line

Hanging engine

Another big milestone day today! Started by re-configuring the clamp block assembly as per plans. Then prepared for engine hanging by attached some straps to the engine mount and the front of the engine. I used my tractor to lift the engine and position it in place. Had a few minutes of help from HVAC guys who were here looking at a problem with one of our house furnaces. They offer to help position engine so I took them up on the offer. After a few minutes the bolts were placed and torqued as per plans. Now the plane is no longer tail heavy. A good milestone accomplished!

Time: 1.5 hrs.

Clamp Block repositioned

Preparing to lift engine

Placing straps for engine lifting

Engine mounted

Engine mounted

Drip pans installed

Drilled right hole in nose gear assembly. The installed carburetor drip pans. A "dollop" of fuel tank sealant in area underneath carburetors as per plans and allowed to set for 1 1/2 hrs before reinstalling the carburetors.

Time: 1.25 hrs.

Bolts ready for engine mount

Right drip pan

Left drip pan

Dollop of fuel sealant

Carburetor installed

Drip pans / drill mount holes

Worked on putting together the carburetor drip pans. This involved riveting some doublers then applying fuel sealant to fill in holes and also to attach a doubler.

I then worked on drilling the holes in nose gear assembly. I was able to finish drilling the left hole as per plans, but due to time will need to continue next time.

Time: 2 hrs.

Drip Pans

Left hole Drilled

Engine installation started.

Engine was revealed today. I unblocked it and used the tractor forks to place the pallet on a table so it is at a better level to work on. The first thing to do was to re-position the water inlet.  A retaining screw was removed at the rear of the ignition module and the wiring harness was separated. A cushion clamp was removed and a bushing placed as per plans.  The trigger coil clearance was checked and was good. I had to run to the store to get some gauges to check clearance. It called for 0.012 - 0.016.  The starter lug was removed as per plans.The lower coolant hose were then remove in preparation for attaching the engine mount.  I then proceed placing the engine mount. This took a little time as it was a very tight fit (plans said it would be). I had to be very careful not to damage the coolant tubes.  Bolt were places and torqued to 30 Ft lbs (360 in lbs) as per the Rotax illustrated parts catalog.  RTV sealant was then places on the VA-216 line as per plans.

Time: 4.25

Engine Revealed

Water inlet repositioned

Retaining screw

Wiring harness disconnected

Bushings placed under cushion clamp

Trigger coil clearance good.

Starter lug removed

Hose disconnected

Mount attached to engine

RTV on VA-216

Firewall FWD Harness 2

Found the starter relay in the Rotax engine box. I installed it and also the Fuel pressure sensor. Wiring was then completed that attached to the manifold pressure sensor, master relay and starter relay.  The plans called for running the wires through a cushion clamp on the engine mount standoff, but I could not see anywhere in the plans were these cushion clamps were called out so I installed some that best fit.

Next session will call for breaking into that rotax box and starting to disassemble some of the engine parts in preparations for mounting the engine.

Time: 2.25 hrs.

Starter relay

Fuel Pressure Sensor

Wiring to manifold pressure sensor

Wiring to master relay

Firewall FWD wiring

Firewall FWD wiring

Firewall FWD Harness

I installed the right panel and mapbox, attaching the GPS 20A to the top of the mapbox.

I then started the Firewall forward wiring harness. This required a few wires to be put through the holes in the bottom of the panel. A little tricky with the transponder installed, but doable. Wires were then placed through grommet in firewall. The pitot tube pieces were then joined with a short piece of tubing and also placed through the firewall.

Battery, master relay, and manifold pressure sensor were then installed. The plans called for installed a starter relay, but I could not locate it. Later in doing some reading on vansairforce it was stated that it is with the engine. I will have to look for it next time.

Time: 2.5 hrs

Mapbox installed

Right panel installed

Battery

Master relay, and Manifold pressure sensor

Battery wire

Firewall FWD harness

Wires nicely tie wrapped