Weight and Balance
With support from the local aircraft works, I did the weighing of the Rebel this morning. I am quite happy with the results: Although I installed a ballistic recovery system …
Fuel Return Line
As recommended by Rotax, we decided to install a fuel return line. This return line protects from vapor locks. It took some time to bend the appropriate 1/4 inch aluminum …
Spinner Problem
Trying to install the spinner, we experienced a problem with the propeller. The propeller already flares out in the radius of the spinner plate. We will have to figure out …
Nose Cowl Work
The MC-7 nose cowl has nothing appropriate for the cowling doors to sit on. So I installed an aluminum strip along the edge of the cowl. The cowling doors can …
Improved Flap Handle
Having nice wooden flight sticks, my wife also wanted an appropriate improved (better looking) flap handle. With the support of a friend in “wood business” I fabricated the wooden flap …
Finishing Cowling
It was still rather cold in the garage. So we reduced our work in February and March. Nevertheless progress was made on the cowling. Picture below shows all parts of …
Test fitting spinner
All cowling doors are finished. So the first phase of the cowling is done. Before doing the final hole drilling I did a test fit of the spinner. It fits …
Cowling continued
We continued to work on the cowling. On the left side of the cowling we needed some more space on the underside due to the exhaust pipe. So …
First Cowling Door
After building the frame for the cowling, the doors are built. I did a mockup with posterboard first and then build the final door from 0.020 aluminum.
Cowling Frame
After we received the spinner, it is clear how much space we need between the spinner plate and the nose bowl. So we could start constructing the cowling frame. I …
EGT Probes
EGT Probes were also welded to the exhaust, 10 cm behind the cylinder. We installed two probes in the two backside cylinders.
Exhaust Welded
A friend welded the exhaust for me. He did a really great job. The TIG-welded parts look great.
Heating Vent
Since our Rebel is heated by water, we installed a water vent inside the cabin (picture is behind the instrument panel). This vent controls the water flow to the heat …
Carburater Heat Control
Placed the control knob for the carburator heat in the panel. Panel is now hopefully complete. In the picture you can see the starter key, on the right there is …
Bowdencable at Airbox
Fixed the bowden cable for carburator heat at the airbox. Unfortunately Rotax did not have a proper end here for the …
Radiator Mounting
It took me some time to find a good position for the water radiator of the Rotax. Most installations put the radiator to the front of the cowling. I …
Fuel Line Routing Left
Picture shows the fuel line routing on the pilot side. It is not an easy routing because of the other tubes on the left side. Nevertheless it all fits …
Cowling Mockup
To check the design of the cowling I used cardboard to build a mockup. Cardboard will be replaced by aluminum later.
Nose Cowling
We decided to install the Thorp T-18 nose bowl (MC-7 from Aircraft Spruce). Its just a matter of design and this one looked best for us. The cowling itself …
Transponder Antenna
Transponder Antenna is installed on the bottom of the fuselage. I installed a doubler inside.
Propeller
There it is, our propeller. I decided to go for a 3 blade ground adjustable propeller. It has a size of 1,82 m and should be good for our Rotax. …
Propeller Spacer
Propeller and prop spacer arrived today. Another important part of the plane. Since we want to use the MC-7 cowl from Aircraft Spruce we need a spacer for the propeller. …
VHF Antenna Including Doubler
I decided to install the VHF Antenna in the tailcone. I think it is best for transmission (no wings disturbing transmission). A doubler (0.032) was installed in the tailcone …
Headphone Jack Boxes Finished
The headphone jack boxes are done on both sides. Today I finished the second box on the passenger side. We tested the connections and its ok. Easy to access on …
Headphone Jack Box
I also did the headphone jack box today. I decided to go for two boxes, one on the pilot side (shown here) and an identical one on the other side. …
Left Side Exhaust Pipes
Picture shows the right side of the exhaust pipes. Before constructing and cutting them I had to fix the exhaust muffler. This was not easy since there is …
Exhaust Pipes
Today I did the exhaust pipes. This is a really exhausting job. Every piece needs to be measured and exactly cut. Picture shows the right side exhaust pipes. I fixed …
Cabin Heater Installed
The heat exchanger from a VW sedan is installed at the passenger side. The two computer fans will be controlled by a power unit, which allows continous adjustment of speed. …
Cabin Heater Construction
We are waiting for the cowling parts to arrive. Propeller and nose cowl are ordered, but it takes some time to get them. During the waiting time, we are doing …
Airbox Issue Solved
The Rotax Airbox did not fit to my installation at the beginning. The airbox conflicted with the motor mount. I long considered how to solve the problem. Discussions with …