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rowlandcarson(at)gmail.co
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 Posted: Sun Nov 18, 2018 10:57 am Post subject: order of assembly for cooling duct, radiators and hoses |
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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
| Rowland Carson ... that's Rowland with a 'w' ...
| <rowlandcarson(at)gmail.com> http://www.rowlandcarson.org.uk
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h&jeuropa
Joined: 07 Nov 2006
Posts: 645
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| Posted: Mon Nov 19, 2018 5:31 am Post subject: Re: order of assembly for cooling duct, radiators and hoses |
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Rowland,
We just took the engine (914) and factory cowl/duct off our XS for maintenance, so got reacquainted with the sequence.
We mount the oil cooler in the duct first. It is on spacers so it sits low.
Attach the duct with the bolts to the footwells, so it is located but can still pivot on those.
Attach the oil lines to the cooler. Access to the fittings is good.
Install the coolant radiator. It will need washers for spacers on the sides. We use a product called Stick It temporary adhesive (it’s a sticky adhesive but heavy grease would work too) to hold the washers in place. The radiator mounts up high in the duct. We added a drain fitting on the bottom port side of the radiator. It makes it a lot easier and less mess when subsequently removing the radiator.
Swing the duct into place and attach the coolant hoses. Use clamps with hex screws and you can reach them with a long extension. We reach the clamps from the port side.
Attach the side plates (CD4 & CD5) to the footwells and secure the duct with the side bolts. Be sure you have nutplates on the interior of the duct for these.
With the factory setup it is important that all the air entering the duct goes through the radiators; there can be no air leaks. We use aluminum tape, rubber strips and weather stripping. We even tape between the bottom of the coolant radiator and the top of the oil cooler.
We fit Thermo Shield on all hoses.
Jim & Heather
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