The Process Of Engine Attachment To An Ultra Light Airplane

Views:
 
     
 

Presentation Description

This post is a step by step guide on how to attach an engine to an ultra light airplane. Each step is divided into different sections to create better clarity and understanding amongst the interested group. So without much ado, let’s start with the process of engine installation.

Comments

Presentation Transcript

slide 1:

The Process Of Engine Attachment To An Ultra Light Airplane: An Overview This post is a step by step guide on how to attach an engine to an ultra light airplane. Each step is divided into different sections to create better clarity and understanding amongst the interested group. So without much ado let’s start with the process of engine installation. SECTION A: The Firewall Assembly Follow the blueprint data and cut the firewall according to the given pattern. Use either 0.032 or 0.040 aluminum. Now make use of blueprint PDF template sheet to fabricate the firewall from the aluminum sheet. Take the scissors and start cutting the template sheet into a specific size. Temporarily attach this cutting to the aluminum sheet with the help of spray adhesive. Cut the aluminum with metal snips and mark the templates’ top contour on the sheet metal with a felt tip pen. Trim all the extra material. Now use the brake to bend the bottom lip so that it fits under the fuselage and start drilling holes at the engine mount locations. SECTION B: Assembling The Engine Mount First of all make sure all bolts and fasteners associated with the engine are torqued according to the engine manufacturer’s owner’s manual 1. Use bolts and hardware to attach the engine mount to the fuselage. In between the engine mount and the firewall use fender washers. Now with the help of supplied engine rubber mounts bolts and lock nuts install the engine to the engine mount.

slide 2:

2. Let’s come to the muffler attachment now. Hang the muffler from the bottom engine mounts locations using tangs and swaged cables. SECTION C: Fuel And Control Line Installation 1. Drill the firewall for pass-thru grommets and don’t forget to deburr the holes after drilling. You need minimum of four holes one for starter delay one for battery one for throttle and one for the fuel line. 2. Run fuel line from the cockpit to the fuel pump. Make sure you use approved fuel line only. 3. At the selector valve put a hose clamp on the fuel supply line and install the fuel filter just before the valve. From the fuel filter route the line forward to the engine. To protect the fuel line use a small piece of thin plastic tubing under the fuselage tubing alongside the rudder pedal. Remember Your fuel line should not kink chafe or pinch. In the forward edge of the floorboard drill a small hole and tie-wrap the line at that point. 4. It’s time to make electrical connections now. Before making one it is recommended to use only high quality electrical connectors and solder all termination points well. 5. Now position the throttle cable in such a way that when the carburetor is at the idle position the lever is aft and low to clear of the door sill. SECTION D: All About Cowling Installation 1. There should always be a large amount of clearance between the engine and the cowl. 2. On the aft end of the cowling top make a center line mark as a visual aid to align the cowling. 3. For making the face of the cowling and the face of the prop drive pulley nearly parallel as possible properly trim the top contour of the firewall. 4. Juggle all the parameters of the cowling fit until you are satisfied. Now drill through the cowlings and centers of the attach tabs and cleco the cowling in place. Make whatever minor adjustments you want as it is the last chance to do this. 5. Remove the cowling and enlarge the pilot holes in the tabs. Start with the installation of nut plates on the tabs now. 6. Start trimming the cowling as necessary to clear all components. SECTION E: Other Considerations Related To Engine There will be many other wires passing through the firewall which will include airplane tachometer cylinder head temperature gauge probe exhaust gas temperature gauge probe along

slide 3:

with the wires you have already run. Just make sure the engine is grounded to the airframe like the engine kill switch. Don’t forget to get everything verified with someone who is familiar with engine installations. SECTION F: Installing Propeller 1. For propeller installation mount the prop to the drive pulley using the centering and crushed plate. Now torque the bolts with engine and safety wire them. 2. Time to check the propeller checking according to the instructions. SECTION G: The Final Checks Before The Run 1. Acquire specific info about the fuel types and grades along with their proper mixing ratio. 2. Fuel system integrity should be up to the mark. 3. Properly check every connection and installation. 4. Now start the engine and run it just to verify that the engine gauges are functioning well. Stop it and check for leaks now. If everything seems normal it’s time to proceed. Hope this post will make you fully aware Resource: https://storify.com/superiorlabsinc/the-process-of-engine-attachment-to-an-ultra- light

authorStream Live Help