Apr 19, 2024     Oil Cooler & Lines - (4 hours)       Category: Engine

Added the fittings and brackets to the oil cooler. Ran the oil lines from the oil tank to the cooler, cooler to oil pump, two bottom returns to oil tank. As others have noticed there was some residual oil that drains out when removing the lower plugs so I was ready with a funnel. The left side plug is better to open first as the oil will drain out of that side that has much more access for a funnel than the right side.

  Apr 07, 2024     Engine Bolts Torqued - (2.5 hours)       Category: Engine

Got the engine lift back out to take most of the weight off the bolts while doing the engine to engine mount torque process. Even though the engine has been on for a while, needed to get a clarification from the factory on torque value and whether to use oil on the threads as the instruction manual says. It didn't sound right to use oiled threads and the factory clarification is to not use any (so the instructions are incorrect).

The top two M10 bolts are simple, the bottom two bolts are difficult due to the access. I had made the needed modified wrench in the past but had to modify it more to get the final torque values done. The wrench kept slipping off with the higher torque so had to do several cycles of tool modification. It was more time modifying the tool than doing the actual bolt torque process.

  Feb 27, 2024     Intercooler - (5 hours)       Category: Engine

Cut the various hoses for the intercooler connection and started to test fit to the engine. It looks like some more adjustments will be needed before final placement with the cowling on, but have a good starting point. Installed the solenoid valve on the firewall and began looking at how to secure the lines. One of the three rivnuts in the firewall started to spin with the bolt half way in, so will need to deal with that once I remove the topskin. The instructions are silent on many of the intercooler steps so requires looking at several pictures and interpreting.

  Feb 26, 2024     Coolant Lines - (3 hours)       Category: Engine

Installed the right/left coolant lines and hoses to the firewall connectors. Once the cowl and radiator are fitted, the right/left lines may need some adjustment before securing the hoses with standoffs.

  Feb 25, 2024     Coolant Lines - (5 hours)       Category: Engine

Began working on the coolant lines installation. Changed the Rotax stock 90 degree interface on back of engine to the straight Sling adapter. Connected the coolant line to engine fill cap. Measured placement and inserted the two T fittings in the L/R coolant lines. Began wrapping L/R lines with the heat shield material and safety wired.

  Feb 08, 2024     Exhaust Pipe - (4 hours)       Category: Engine

Did some final grinding on the exhaust pipe to smooth and round the edges where needed and remove any burrs from the cutting process. The two brackets that hold the Sling exhaust pipe on are different sizes with the small one going onto the remaining stock exhaust section. I found it easier to put the bracket on the stock exhaust first and then push the Sling exhaust on so that the thickness of both items didn't have to push through the available gap with the support flange. Once on then added second bracket and snug tightened both brackets for now. Once the cowling and exhaust fiberglass are fitted I may need to change the angle of the Sling exhaust slightly so will fully tighten down then.

Added the intercooler support brackets.

Test fit the wheel pants and began reviewing where the holes need to be drilled.

  Feb 07, 2024     Exhaust Pipe - (2 hours)       Category: Engine

Completed the removal of the stock exhaust pipe. The most challenging part was to grind enough of the weld seam that was still holding in the half moon shaped part of the original stock pipe without damaging the support bracket. Once one side was ground down enough it broke free and was easy to remove then.

  Feb 06, 2024     Airbox/Exhaust - (4 hours)       Category: Engine

Constructed the airbox

Cut off the stock exhaust. Still need to do some grinding on the inside of the flange so the TSi exhaust pipe will fit on.

  Jan 20, 2024     Engine Install - (3 hours)       Category: Engine

Initial installation of engine complete. Waiting to torque the mount bolts until I get a clarification from the factory on the torque value. Overall it was fairly straightforward to hang the engine and thankfully the two bottom bolts that were shortened were still long enough to catch the threads of the nyloc nut to get started.

It takes help to build a plane and I want to gratefully mention the assistance from Tom White (including borrowing his engine hoist) and Greg Schroeder, who are both EAA Chapter 168 members and 52F hangar neighbors. It wasn't just the extra hands but the advice on several things that was appreciated as a first time builder.

  Dec 01, 2023     Engine Delivered - (2 hours)       Category: Engine

Freight company delivered Rotax engine, spent some time unboxing the various parts that come in the crate in addition to the engine. Given how far this crate had traveled, I was pleased there was no damage anywhere to be seen. From order date to delivery was Feb 14, 2023 to Dec 1, 2023.

Downloaded and started reading the Rotax installation manual.