Photograph Engine and Start Removing Parts

This morning I removed the plastic from around the engine and took a dozen or more photographs for reference.  These are a few of them.

After photographing the engine from many different angles I removed, rotated and reinstalled the water inlet elbow on the lower front.  I also labeled the ignition harness electrical connections as shown on the drawings.

I need to find the torque values from the ROTAX manual and torque to bolts on the inlet fitting.  I also removed the  screw from the ignition harness clamp and pulled the harness away.  I also removed the connections from the bracket and pulled them apart.

Firewall Forward Wiring Continues

This afternoon I continued to install the firewall forward wiring.  I stripped the ends of the EGT exhaust  gas temp wiring harness freeing the yellow and red wires.  I stripped the wires and crimped on the male electrical c connectors included.  I also cut the connectors off of the ends of the EGT sensors and crimped new female connectors to those wires.

I installed the wires from the wiring harness into the manifold pressure sensor connector and installed the connector into the sensor mounted on the firewall.  The wires are really long so I coiled them and taped them together.  I also installed the power wiring to and between the master relay and the starter relay.  There are still a lot of wires that need to be connected.  I have coiled them and wire tied them to the engine mount.

Firewall Forward Wiring

It was really cold today.  I opened the garage and moved the forward portion of the fuselage out onto the driveway.  The sun was shining, but the air was cold.  I wore  my shop coat which made the afternoon more tolerable.  I started by removing the canopy and rear window and turtle deck skins.

I also removed the upper fuselage skin and proceeded to work on the wiring.  I installed the WH-00063 Firewall Forward Wiring Harness 25-pin sub D connector to the control module.  I then routed the wires past the cushioned clamp next to the cooling fan and out the firewall grommet.  I could not get the harness into the cushioned clamp so I used a wire tie to connect it to the clamp. I also attached the WH-00062 power wiring harness to the rear of the Power and Switch module and routed the wires thru the fire grommet.  I wire tied the power wires to the bundle of wires going past the Com Supports  I put a clam shell on the EGT 25-pin sub D connector and attached it to the RV-12 EGT Exhaust Gas Temp Wiring Harness and routed the wires thru the wire tie holding the bundle to the cushioned clamp and out the firewall grommet.

It is really tight quarters in the instrument shelf area and I am having trouble routing these new harnesses thru the existing cushioned clamps and snap bushings.  I am holding the harnesses in place by wire tying them to other wires running in the same areas.

I cut a 4" length of PT ¼" ID tube and inserted one end of the ¼" heat resistant tubing for the pitot.  I cut the ¼" pitot tube from the fuselage and inserted the end into the splice tube.  I routed the pitot tube thru the grommet in the firewall.  I coiled it around the GPS antenna shelf.  I also routed the wires from the wiring harnesses

I separated the red, green and black twisted wires from the WH-00063 harness.  I cut them to length, stripped the ends and crimped them to the corresponding colored wires on the fuel pressure sensor.

I inserted the white wires and yellow wire with the spade connectors into the Connector Housing for the Rectifier Regulator.  They snapped into place and a gentle tug assured they were properly seated.  I plugged the connector into the rectifier.  That's all for today.

Fuel Pressure Sensor

This afternoon I installed the battery hold down channel on the battery.  I also installed the fuel pressure sensor on the firewall.  I mounted the bracket on the firewall then using a socket and the vice I modified the grommet.  I installed the grommet in the bracket and inserted the elbow into the grommet.

I used pipe tread sealant on the sensor and then turned it into the elbow.  I then cut the wires and installed splice connections to the wires.

I also installed some rope handles on the Rotax engine box so it is easier to remove and replace over the engine

Firewall Electrical Components

For the past few days I have sorted, moved and checked the inventory on the parts I received last week.  I also reinstalled the top on the Rotax box.  I removed the box from the bottom so it is now a cover I can remove and work on the engine as needed.

Today I started to install the electrical components on the firewall.  I started by prepping the battery area.  I primed and painted the batter hold down channel and cut the battery spacers from the T6 aluminum tube.

I installed the Master Relay, the Starter Relay, the Manifold Pressure Sensor and the Rectifier Regulator.  

I also installed the ground wires (P-149 & P-151)  to the Oil Reservoir Brace and the Power Cable (P-150) to the battery terminal.  I caped and taped the end of the Power Cable to the fire wall.

Pick-Up and Inventory Engine and Propeller

 Yesterday I received a call from ABF Freight Systems saying they had a delivery for me.  They also said it weighs about 400 lbs and I would need some help getting it off of the truck.  I told them I would come to their dock and pick-it up myself.  I drove to ABF's dock in Salt Lake City in the early afternoon and they put the crate in my pick-up truck.  I drove home and started the  unloading process.  It was a pleasant afternoon so I was able to enjoy the weather.  That is not going to be the case for much longer.  I slid the crate to the rear of the truck and removed the lid.  What treasures I found inside.

There was a ton of paper inside.  I pulled it out and found some scat tube, heat reflective film and the fiberglass cooling shroud for the radiators and for the engine.  I also found the muffler and exhaust pipes in the mass of paper dunage.  I removed the 2x supports and removed the box containing the prop.  I opened the box.  It is a good looking propeller.  Next I removed the end of the crate.  I started pulling out some additional loosely packed bags and packages.  Gee, this is like Christmas.

I removed the end of the shipping crate to expose the engine package.  I pulled the work table on wheels I prepared for the engine.  I assumed I would be able to put the engine on this table and roll it around the garage to work on it until I am ready to install the Rotax on the airplane.  I think my assumption is going to work out very well.  I was able to pull the engine box out of the shipping crate onto the work table without too much difficulty.  I was then able to roll it into the garage.  I have placed the various parts in various locations for now.  I will do some relocating and sorting in the next couple of days.

With all of the excitement, I opened the engine box to peer at the Rotax.  There it is in all of its glory.

I continued to open boxes and bags and did a complete inventory.  To the best of my ability, it appears the only thing missing is a small part on back-order.  I will begin working on the installation soon.