FWF OP 62 Kit mods for EXP119

  

RV14 Build March/April 21

Exp119 Mods

Starting off with the mods is the cowl flap or exhaust tunnel flap. Simple enough, gather the parts, prime, assemble.

Prime

Assemble

Adding nutplates and cushion clamps.

Time to drill the nutplate locations.

Drilling. The hard part is how do you dimple the skin. I pruchased a bit that fits into the rivet gun that will hold a dimple die and if I drill a hole into a bucking bar to hold the other end of the dimple die I can smash it into submission. Or I bought some oversized rivets/oops rivets for AN-2 with smaller heads than -3 that will just night a slight countersinking. still TBD.

Nutplate loctions.

I was back and forth on adding another firewall pass through like the one above it or the special one that hold 2 cables. In the end I decided to use the special one with the kit.

Fitting the snorkel is detailed in the whole baffle section but here is the part that is OP62.

The snorkel interferes with the cylinder 2 oil return line. So disconnected it for now.

After I fit the snorkel I realized the baffle was pushed out by the cylinder heater elements. So I removed the baffle and trimmed it. of course I had to start from the beginning on fitting the snorkel since everything shifted.

Finally a good fit.

Drilled holes for clekoes and I fluxed the top abne bottom of the snorkel parts together. 

The fuel flow sender mount plate.

I had to add spacers under the plate before the cushion claps. This allowed the sender to sit away from the oil sump a little better.

Exp119 Mods 22.0 Hours

FWF 43 and Inventory: Engine Install, Pmag and B7C Filter install

 

RV14 Build March/April 21

Engine Installation

This section has a lot of work and a lot of optional work. But First the Inventory.

Only a partial inventory since the whole kit wasn't ready.

New bottom Cowl.

The inventory went fairly quick now on to the build. The plans have you start off with the relays

Silver is the Battery and Black is the Starter

The picture is a little cockeyes but there they are installed with the main bus bar connecting.

The rest of the wires getting connected and all the FWF wires getting pulled and organized.

Time to prep the motor! Getting it out of the box was a little tricky since the foam had formed around it.

First Flight for this motor

Oil filter and adapter has to come off.

BandC Upright Oil filter with 1.4" Adaptor

Vernatherm installed. This get torqued to 300in/lbs

Other view of the vernatherm

Gasket sealant on all the gaskets, bolt are torqued.

Filter installed. Along with all the hoses and fitting on the back of the engine.

Next I installed the Pmag. I had to replace the Lycoming studs for shorter ones, but didn't get a picture of that. But here is the lycoming gear installed, torque and cotter pinned.

Im going to wait to torque this in position till i know how all the hoses will go.

New old magneto off.

The install manual for the Pmags warns against using the clamping mounts for ground so I made this terminal to connect to the grounding strap for both Pmag grounds.

I really wanted to install the Rieff heater Turbo kit, but the IO-390C oil sump doesn't have a flat spot to bond the heaters to. I thought I found one but the heater was too long.

I did install the cylinder heaters so at least Ill have something. Just have to plan further ahead when I want to fly.

You can get these on without removing the inner cylinder baffles which is really nice. I did trim my baffles to have a little clearance where needed.

Setting the clocking on the prop governor. I did have to loosen the arm nut and change its orientation to get the cocking to be correct.

Almost ready for the big lift!

Orientation for the top hardware.

Top ones pre loaded, gonna go for the top right first, thats what ive read is easiest.

In position.

Big lift. We had some trouble getting the motor and airframe aligned correctly but once we got the first bolt in the second was soon to follow. We had to slightly tilt the motor up to get the bottom pucks in and start the bottom bolts. Once the started we lowered the motor and everything self aligned. All in it took 45 mins to get all 4 bolts. Huge shoutout to Bill, couldn't have done it without you.

Second boltt in but still loose.

Excited nervous face.

All in and torqued to the standard AN7.

The prop governor seemed like the studs might be too short so i went with a smaller washer to get at least 1 thread to show.

The started cable is too long.

Not anymore!

Have to go online to find the installation for the alternator.

Getting all the parts ready.

Torque and safety wire the bolts

All installed and looking good.

or so i think. The alternator looks like its 1/32 of an inch too far aft. The belt has a slight twist and bend in it from the mis alignment.

FWF INV and FWF Section 43 Engine Install 31.5 Man Hours