Category: Firewall Forward

I received back my fuel pump assembly from Lockwood Aero, which was updated to comply with ASB 915 i-012. This fuel pump was the last thing I wanted to install before installing the top skin just aft of the firewall. The nuts that secure this pump assembly are on...

Before closing out the skin above the firewall, I really wanted to address an Alert Service Bulletin (ASB) issued by Rotax in 2022 against the factory fuel pumps. The fuel pumps attach through the firewall and are secured on the inside with lock nuts that are not easy to...

The firewall has a large opening, necessary to allow the large connectors to the Rotax ECU to pass through. The included close-out plates don’t seal up the hole nearly enough so I bought an off-the-shelf firewall grommet. It comes in two pieces that join together. I riveted this to...

(March 4, 2023) Just sharing a quick blurb about an easy change to the Rotax wire harness that makes it easier to connect the fuel pumps. The as-built wire harness on the engine isn’t quite long enough to reach one of the two fuel pumps, due to the orientation...

(March 11, 2023) I wanted to cut the coolant hoses to the proper length, so I decided to first attach the radiators to the lower engine cowling and then temporarily attach the cowling. The oil cooler fit no problem, but the water radiator required some grinding away of material....

The instructions for installing the exhaust pipe are only three steps on one sheet, but the task took me a solid 4 hours to complete because I was trying to be careful. The installation of swept tail pipe requires removal of the stock straight pipe, which is welded in...

Last night’s task was installing the air filter assembly. I had to make a few modification when fitting the two manifold absolute pressure sensors to the filter housing:...

I completed most of the engine oil lines in early November but when I started to build the oil radiator supply line I discovered that the fittings I had for the oil tank and for the oil pump were the wrong size. A visit to the illustrated parts manual...

I built up the oil hoses that connect between the engine oil returns and the oil tank. Per the build manual, these hoses are to be covered with a heat shield, and then secured with lock wire. I briefly talked about the heat shield with Shawn during a recent...

For the first major task following mounting of the engine, I began installation of the fuel lines. I thought this would be pretty easy, but it took two full days and I learned a few things. At first I was going to use aluminum tubing, much like I did...