Title: Battery Tray, Cabin Heat Valve and Brake Fluid Reservoir
I met my weekly goal for the first week of phase 5. I worked to improve my list of things that need to be done before I hang the engine. I decided to take apart the B&C starter contactor. As I suspected, it is a solid design and would have worked well if it didn't create mounting problems for me. See below for pictures of the contactor, brass contacts in the housing and the thick disk that bridges the contacts. I did a little more research on starters since my Lycoming engine documentation lists the Lycoming part number for the Hartzel (Sky-Tec) starter, but I couldn't find any website that had a cross reference. I installed the nut plates on the back of the battery tray using the small head NAS rivets. Then I enlarged the clearance holes in the firewall as needed so the bolts would line up with the nut plates. All done! Then it was time to cut the large 1.95" hole for the cabin heat valve. I used a step drill to get to the 3/4" hole I needed for my hydraulic punch. Then I used the Harbor Freight hydraulic punch and it worked great. There was a small, sharp ridge around the hole that I removed using a small drum sander on a battery powered drill. I was pleased that the hole was only about 0.020" to the pilot side and about 0.010" low from where the center should have been. I figured the location would be worse with all the steps it took to finish the hole. I was ready to drill the two holes that are used to attach the cabin heat valve to the firewall and realized I didn't know the exact orientation. I searched drawings and websites and found one website that showed the valve oriented in a way that makes sense to me, but I'm going to wait until after I hang the engine before I drill the holes. I marked the holes for the brake fluid reservoir. Then I drilled the hole for the reservoir outlet. Then I drilled undersized holes to mount the reservoir and filed the reservoir and firewall holes for the final fit. I spent about 8 hours on the project and research today and only logged 6 hours which was more than enough to meet my weekly goal.


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