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budyerly(at)msn.com
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 Posted: Sun Nov 18, 2018 6:11 pm Post subject: order of assembly for cooling duct, radiators and hoses |
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Rowland,
Just a quick note on the FWF for a Europa.
Make your life easy and install nutplates for as much as you can. Get proper tools for dimpling metal, the TAPK 33 and 36 rivets are fine for FWF work. Install nutplates in the cowl.. I don’t use camlocks or quick releases as they get dropped, lost, break, and are of many different lengths. I use 507 stainless AN screws from 1/2 down the sides, 5/8, and ¾ to 1 inch for the circumference and longer ones for the lower cowl area.
All ducting mounted to the aircraft should be on nutplates. Contact me off line for how to do cowl nutplates single handedly.
Once the engine is on, level and with proper offset, fit your spinner backplate to the prop flange. Install your exhaust system.
The CKT exhaust must be installed as far aft as is possible for proper clearance. The Rotax muffler should be as far aft as possible also. Make sure the exhaust knuckles or cups in the muffler are properly sealed.
Fit the cowl next and make sure the it is aligned with the spinner. Don’t make the mistake of fitting the back first then the sides. Tape the lower cowl on first. Yes use painters tape. It is best to get a good fit down the sides. Then check if the cowl must be cut to clear the muffler, exhaust pipes, etc. Mark the lower cowl for aft side fit. I like 1/8 inch from the spinner and its backplate to the cowl. Install a cleco if you have to in the lower cowl and tape the front of the cowl to the spinner/backplate to hold the front up. The upper cowl goes on next. It may overhang a bit. Trim the upper for a smooth fit. Cleco together to a nice smooth finish pulling the upper cowl as you drill for a tight fit. Then apply the rest of the clecos.
Pull the cowl when satisfied.
Install the ducting next. It’s a waste to paint it first. Get it clearanced and fitted first.
Plan for access to your hose clamps. Trial fit the radiator and oil cooler for proper fastener clearance and orientation. Usually one ¼ inch bolt for the radiator doubles as a brace bolt also. A thin set of ignition wrenches works to hold the bolt heads during install with the nuts on the outboard side. The starboard side brace can use a hole to get to the radiator clamp. I like to get to the oil ones via the top or back. Yes a long extension can get to the hose clamps on a normal trigear, but for the mono/Singleton firewall you must get it on from the back. Always Clearance around the muffler on the port side. Cut that half moon that is there out a bit more to suite... Yes some of the metal on the duct can be cut down a bit. Drill and cleco per the manual. This will make any changes to your hoses and whatnot a simple task of a few seconds with a ratcheting wrench. Don’t fret about the two nutplates in the rear duct. Use a Dremel with a Permagrit or other routing bit and make your relief of the fire wall material and dimple your nutplate and rivet it home.
Finally, don’t forget that a couple of special tools will make your job easier. Make a short wrench to support and tighten the oil fittings by cutting off existing proper wrenches to fit.
See my cooling 101 article on my website to get ducting ideas.
Best Regards,
Bud Yerly
Custom Flight Creations, Inc.
Sent from Mail for Windows 10
From: owner-europa-list-server(at)matronics.com <owner-europa-list-server(at)matronics.com> on behalf of Rowland Carson <rowlandcarson(at)gmail.com>
Sent: Sunday, November 18, 2018 1:48:14 PM
To: Europa e-mail list
Subject: order of assembly for cooling duct, radiators and hoses
--> Europa-List message posted by: Rowland Carson <rowlandcarson(at)gmail.com>
I’m trying to figure out the optimum sequence of assembly (or even a sequence that is possible!) for the various cooling items on my XS monowheel, with Neville Eyre cowl and Rotax 912S.
I’ve listed which things need to be done before others - eg:
The long bolts and spacers securing the oil cooler will be much easier to fit before the duct is mounted to the firewall.
The bolts holding the duct sides to the CD4/CD5 brackets are obstructed by the oil cooler and water radiator, so need to be fitted first
The hose clips for the oil cooler connexions are hidden by the water radiator so need to be fitted before the radiator is installed (or can I get at them from the aft side?)
The hose clips for the water radiator connexions will be out on top of the duct so should be fitted before the duct is installed (or can I get at them by reaching down through the engine mount?)
. . . and so it goes on . . .
Has anyone got a sequence of assembly that works? Or on the other had, can anyone offer suggestions about what definitely NOT to do?
in friendship
Rowland
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