Remove Main Gear

I disconnected the right and left brake lines at the mounting brackets.  I removed the left gear leg by removing the bolts on the inboard and outboard brackets.  The gear leg came out without any trouble.

Next I removed the right gear leg.

Started SB 12-11-09 – Landing Gear Attachment Mod

I started the SB 12-11-09 mod this afternoon.  I started my reconfiguring the airplane in the garage.  I moved it into Arlene's parking space.  She will park outside until I am finished with the mod.  I removed the rear baggage area upholstery and the cockpit seats.  I removed the ELT antennae bracket and removed the ELT from its mount.  

I removed the fuel tank.  I am planning to make the fuel tank sump mod before I reinstall the tank.  I will not install the mod until after the airplane is certified.  I removed the cushioned clamps at the outboard ends of the flexible conduit running the mid channel. 

I had Arlene help me put saw horses under the fuselage.  These are metal saw horses and are capable of supporting the weight of the fuselage and the engine.  I put a saw horse under the front support rib and lowered the nose.  I had to put a block under the nose wheel to level the airplane.

I put a second saw horse under the tail for added stability.  I am now ready to start removing the gear.

Replace Lower Banjo Bolt and Fitting

This was a shorter day.  I removed the lower Banjo Bolt and the oil began running out of the crank case.  I put the bolt and fitting back in the opening and cleaned up the oil spill.  I suspended a bucket under the engine and removed the bolt and fitting once more.  I allowed the oil to drain until it stopped.  I used one of the copper washers to install the new replacement fitting from Rotax.  After torquing the fitting to 15 ft lbs I removed the yellow cap from the original fitting and put it on the replacement fitting.  

Section 46 is now complete.

Miscellaneous Wiring and Fuel Drain

This afternoon I worked on different wiring sections.  I installed the ignition wiring harness to the A1 and B1 electrical connectors.  I removed the metal clamp from the Ignition Module A and inserted the exposed shielding of the harness and reinstalled the clamp.  I routed the harness to the rear of the engine and cable tied it in place.  I inserted the wires from the main wiring bundle through the firewall into the female connector and then put the connectors together.  I  also located the ‘forked’ purple wire from the main bundle and routed it back to the Ignition Module.  I removed the A2 and B2 connectors from the metal bracket, removed the seal plugs and inserted the wires into the connectors.  I then reassemble the connectors and reattached them to the metal bracket.  I cable tied the purple wire to the pitot tube.

I located the Oil Pressure wires (red, white/yellow) in the main bundle and crimped on the appropriate spade terminals.  I routed the gray Oil Pressure cable to the rear of the engine and up to the engine shelf.   I cut it to length and attached the appropriate spade terminals and connected them to the red & white/yellow wire spade terminals.  I ran the purple/blue right CHT (cylinder head temperature) wire down to the bottom of the engine, crimped on the terminal and attached it to the  CHT terminal post.  I also ran the purple/yellow left CHT wire and the white/brown Oil Temperature wire down to the bottom of the engine and crimped on the terminals and attached them to the appropriate terminal posts.

I ran the Generator to Rectifier cable to the engine shelf and attached the ends to the Rectifier terminal block.  I also ran the Tachometer cable to the engine shelf and made the necessary attachment to the wires from the main bundle.  I put cable ties on all of the wires to secure them in place.   I attached the ground wire and the starter power cable to the starter.

I cut the rubber hose to make the manifold pressure tubing and installed it from the nipple on the compensating tube assembly to the nipple on the manifold pressure sensor.  I also cut the rubber hose to make the fuel pump drain line.  I straightened the ¼” aluminum tubing and fabricated the drain tube.  I installed the drain line, both rubber and aluminum tubing and installed the pipe clamps, cushioned clamps and cable ties to hold it in place.

Banjo Bolt and Fuel Lines

The BANJO BOLT I had to order arrived this afternoon.  This evening after going flying for 1.3 hours I installed the banjo bolt and fuel lines to the bottom of the clamp block.  I then routed the fuel line to the fuel pressure sensor and attached it to the elbow on the fuel sensor.  I routed the fuel return line to the fitting on the engine shelf and attached it there.  I also routed the fuel line from the fuel pump across the top of the cooing shroud and down to the gascolator and attached it there.  I cable tied the fuel pressure sensor line to the compensating tube assembly and the bracket on the carburetor as shown.  I hope to continue with the installation of the electrical wiring tomorrow.