Cooling Duct

Worked on the cooling duct today. Started by trimming the cooling duct and interface to the trim line. This took some time. I then attached the oil cooler to the cooling duct. The duct was then tried into place. It was aligned as per plans and then holes drilled and clecoed to the bottom cowl. Once everything looked good the cowl was removed.

Time: 3.25 hrs

Oil Cooler attached to Cooling duct

Cooling duct fitted into place.

Drilled and clecoed

Inside view

Oil Cooler Frame

Put together the oil cooler and oil cooler frame. It involved placing some RTV in a few places while riveting the frame together. Now time to let it set.

Time: 0.75

Oil Cooler and Frame

Heat push cable / radiator

Continued work on the cooling system. I installed the heat push cable. This required placing some cushion clamps on the engine mount. It took a little work to get the cushion clamps installed due to being in a tight space, but eventually got it. Just one of those things that takes a little longer than planned. I attached the cable to the cooler box door as per plans. The radiator was then placed. I also took the opportunity to place fuel tank sealant over the rivets that were installed for the cooler box.  The radiator hoses were then attached. I placed RTV in a few places that looked like they would rub. 

Time 3.25 hrs

Heat push cable

Heat cable

Heat cable

Cooler box door

Radiator

Upper radiator hose

Lower radiator hose.

Cooling System 2

Continued work on the cooling system. I applied RTV to create the cooler box door gasket. I also placed RTV in a few other areas around the engine where parts might rub. 

Time: 0.5 hrs.

Cooler door box

RTV added

RTV added

RTV added

Cooling System 1

I was able to get a good start on the cooling system. I started by cutting lengths of radiator hose and placing springs in them as per plans. I then worked on the cooler box assembly by cutting the stainless steel hinge and attaching the cooler box assembly to firewall.

I need to purchase some more high temp RTV sealant to create the seal so I skipped a few steps for now and installed the oil tank assembly.  The oil vent was installed. It required placing a cushion clamp at the location of the gascolator. This was very tricky as there wasn't much room to work in, but I finally got it accomplished.

The overflow bottle was installed along with the overflow tubing which then attached to stem on the expansion tank assembly.

Time: 3

Cooler box face & hinge

Cooling box structure installed

Oil tank assembly

Oil vent line

Oil vent line in cushion clamp

Overflow bottle

Overflow bottle hose attached

Exhaust System

Started and finished exhaust system today. First place and loosely tightened nuts for exhaust pipes. The springs were then used to attach the muffler. The lower cowl was placed to check for clearance of opening. The muffler was positioned so that there was adequate clearance between muffler pipe and cowl. The nuts were then torqued as per plans. The EGT probes were placed with hose clamps and the wire ran as per plans. I then spent a few moments going through and placing zip ties to wires in the engine area to get them cleaned up.

Time: 1.75 hrs

Left side muffler

Right side muffler

Lower cowl in place

Exhaust hole clearance checked

Left EGT probe

Right EGT Probe

Cowl Complete

Completed section 38 today. Started by riveting all the hinges to the cowlings. The cowling were then put in place and edges sanded to fit. Plans call for 1/32 inch gap.The 6 holes in front of the cowling were enlarged and nutplates riveted to the lower cowl. The oil door opening was cut in the upper cowling and the oil door fabricated and riveted into place.There was a slight interference with the door opening so it required a little removal of the upper edge of the door.  The lower close out was then made per plans and nutplates attached.  It is nice to have this section done. Now I can get back to doing engine work. 

Time: 4.5 hrs

Riveting side hinges

Cowls in place

Nutplates attached on lower cowl

Oil Door opening

Oil door set in place

Camlock receptacles

Oil Door attached

Bottom closeout

Upper and Lower cowl finished