Mar 30, 2024     FF1_10 Engine Installation - (1 hour)       Category: Engine

Installed the firewall passthrough. Reinstalled one of the shunt as it was mounted upside down. Checked firmness of all components. Installed the steel shield for the air control cables. Installed all the screws in the eyeballs passthrough.

  Mar 29, 2024     FF1_10 Engine Installation - (1 hour)       Category: Engine

Glued the fiberfrax steel foil assembly to the firewall (top area). Used aluminum adhesive foil to cover the fiberfrax gap.
Installed the brake reservoir with the necessary spacer.
Installed both ANL and the shunts.
Installed the steel air valve.

  Feb 23, 2024     46-2 Engine Mount and landing gear Step 1 - (2 hours)       Category: Engine

Replaced the AN6-22A with AN6-22. NOT TORQUED.
Installed AN6-25 instead of the undrilled version. Modified the two steel washers to clear the welding.

  Dec 09, 2023     FF2-7 Cowl Baffles step 1-11 - (6 hours)       Category: Engine

Deburred all the parts for baffles for CYL #2, #4, #1, #3. Adapted one of the doubler for baffle CYL #1, Dimpled all the holes, deburred the hols and riveted all the doublers to the baffles.

  Dec 08, 2023     FF2-6 Cowl Baffles step 1-3 - (1 hour) Category: Engine

preassembly of the Cylinder 2 Baffle. Matchdrilled, deburred and dimpled. Riveted the doubler plates

  Dec 08, 2023     FF2-6 Cowl Baffles step 1-8 - (5 hours) Category: Engine

Preassembly of the Cylinder 5 baffle components (CB-1007B, CB-1007A, CB-1007A, CB-1008A).
Drilled the holes as indicate in the Instructions. Installed the Vent-03 DL SCat tube flange, matchdrilled and marked hatched area. Removed hatched area and step drilled the two holes as indicated.
Riveted the CB-1008B stiffener, the CB-1008C and CB-1003C stiffeners after dimpling the inboard side of the CB-1008A.

  Dec 07, 2023     FF2-6 Cowl Baffles step 1-3 - (1.5 hours) Category: Engine

Assembled cylinder 5 baffles. Matchdrilled stiffener and doubler plates.Deburred all the holes and edges

  Dec 07, 2023     FF2-4 Cowl Baffles step 7-11 (missing riveting - (2 hours)       Category: Engine

Matchdrilled and disassembled all the parts, deburred edges and holes. Positioned the CB-1005B Oil Cooler Brace and drawn a rivet line parallel to the lower edge of the cylinder 6 aft baffle. Removed all parts, final drilled #12.
Overall view of the left side engine baffles, #6, #4 and #2 from left to right

  Dec 03, 2023     FF2-4 Cowl Baffles step 1-6 - (2 hours)       Category: Engine

Preliminary assembly of CB-1005A aft baffle, CB-1004A cylinder baffle, CB-1006A left case baffle and CB-1004C stiffener. Matchdrilled the holes with #30 drill.

  Dec 02, 2023     FF2-3 Cowl Baffles step 7-9 - (2 hours) Category: Engine

Riveted the flanged duct. I had to replace ALL the rivets with -5 rivets as the Flange was bulging and removing the rivets resulted in enlarged holes. I am still not super happy with the result but i have not been able to have a better result.

  Dec 01, 2023     FF2-3 Cowl Baffles step 1-6 - (4 hours) Category: Engine

Drilled the four pilot holes. Cut the 4" hole. Enlarged two pilot holes with 3/4" step drill as indicated. Deburred all holes and cuts. Scuffed with scotchbrite.
The riveting of the VA-187 flanged duct has been a nightmare as the riveting with the bucking bar results in warped flange. drilled out few rivets, but got three enlarged holes. Used the squeezer and slightly better result, but still some ondulations are there....I had to use -5 rivets as the holes were too big for the -4 rivets. Not super happy but it will work.

  Nov 30, 2023     FF2-2 Cowl Baffle Step 1-3 - (3 hours) Category: Engine

Separated the different parts CB-1002B, CB-1008B, CB-1010G, CB-1002G, CB-1004C, CB-1010B, CB-1002C, CB-1010C.
Cut as indicated, deburred and rounded all the corners.

  Sep 21, 2023     51 FF1_10-2 Engine Installation step 1-5 - (3 hours)       Category: Engine

Assembled the oil cooler support, final drilled, dimpled, deburred all the holes. Little adjustment necessary to install on the predrilled firewall holes.
Riveted the parts together.
Riveted to the firewall.
Drilled 4 holes to secure fiberfrax/steel sandwich to the interior of the cooler.

  Sep 19, 2023     Oil Cooler Airflow Niagara 2006A Serial K22-16535-96 - (1 hour)       Category: Engine

Following Service Bulletin DOES NOT APPLY for my Oil Cooler as the serial number is NOT in the indicated range.

Service Bulletin from Airflow
2006X X-Series Oil Coolers, manufactured in 2019 with serial numbers K19-16202-25 through 40

Oil Cooler Service Bulletin 0001 – REV A

June 12, 2023
2006X X-Series Oil Coolers, manufactured in 2019 with serial numbers K19-16202-25 through 40.
Potential oil leak from the vanes and/or core area of the oil cooler due to potential manufacturing defect.
The service bulletin only applies to 2006X X-Series Oil Coolers serial numbers K19-16202-25 through 40. We are still collecting data, if your oil cooler is outside the affected range, we are interested in knowing about any failures.
Inspect your 2006X oil cooler data plate and determine if your oil cooler falls within this serial number range. If it does, do not continue to fly your aircraft. Send Airflow Systems an email at airflowsystems2@gmail.com with your contact information and we will send you a replacement oil cooler and return shipping instructions for your oil cooler. DO NOT THROW AWAY YOUR OLD COOLER, WE REQUIRE THEM FOR EXCHANGE AND INSPECTION.

  May 02, 2023     46-2 Engine Mount and landing gear Step 1 - (2.5 hours)       Category: Engine

Fabricated the spacer for the alternator contractor in order to have better clearance for the AWG2 and other cables.

  May 01, 2023     46-2 Engine Mount and landing gear Step 1 - (3 hours)       Category: Engine

matchdrilled the engine mount bolt holes with the help of lucio. Tests fitting of the engine mount.
Decision to fabricate a spacer for the starter contractor.
Decision to fabricate a passthrough for the cabin air vent cables as the solution with eyeball passthrough doesn't seem to work.

  Apr 13, 2023     Documentation check and warranties - (3 hours)       Category: Engine

Finally i had the time to spend some time on the Engine documentation. I read carefully all the service letters, i sent all the registration information to airflow performance. I also prepared a folder with all the documentation for Engine, Airflow injection, MT propeller.

  Apr 05, 2023     FF1_10 Engine Installation - (4 hours)       Category: Engine

As suggested in the KIA i plan to install few items on the firewall before bolting the engine mount. In addition i decided to add a layer of fiberfrax and a stainless steel foil as recommended by Dan Horton.
As starting point i marked the different penetration on the firewall and together with Lucio we worked on the Oil Cooler Support in order to make it fit as it was a bit bent.

  Mar 29, 2023     engine arrived - (0.5 hour)       Category: Engine

  Feb 20, 2023     Firewall Forward Kit Inventory - (2 hours) Category: Engine

firewall forward kit received today. There is a subkit on backorder. Will check with vans on possible delivery due date.