Category: Firewall Forward

The intake at the front is also build from aluminu. Appropriate 2 1/2 inch ducting puts the air to the air cooler in the back.  

Best position for the oil cooler seems to be in the back of the cowling. There is plenty of space and so I decided to put it there, build an …

Fuel hoses are installed. I protected them with special kevlar heat protection tube. Again bought in car tuning shops.

Water cooler is installed. I used silicone hoses. They are better than the normal ones and even cheaper. Easily to get in some car tuning shops. Furthermore the blue colour …

Cutout in the spinner are done. They now have a close fit to the propeller. Fabricating the cutouts is easy and straightforward with a Dremel tool.  

To solve the propeller problem, a friend fabricated a special spacer plate for me. It is really a nice piece of art. Fabricated from aluminum on a computer CNC machine. …

Oil cooler is installed. It is installed in the back of the engine compartment. I will install a special hose to get more air into this position. Oil cooler is …

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 …

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 …

  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.

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 …

                  Fixed the bowden cable for carburator heat at the airbox. Unfortunately Rotax did not have a proper end here for the …

  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 …

To check the design of the cowling I used cardboard to build a mockup. Cardboard will be replaced by aluminum later.  

  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 …

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 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. …

    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 …

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 …

  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 …

Rotax 912S seen from the front. I am planning how to fabricate the cowling. I decided to make my own from aluminum.    

  Engine is installed with Lord shock mounts. The engine mount on the right is the standard one supplied with the engine. Unfortunately the Airbox does not fit to the …

Mounting the engine was much easier than expected. I often thought how to do this and considered to buy a motor lifter. But the Rotax 912 is only about 60 …

  The Rotax unpacked: 100 hp 912 ULS with an airbox. Everything is in the box from Rotax. Additional things we bought are oil vent and water temp vent.

        A great day. We bought a brand new Rotax 912ULS engine. It just fits into my car, so the last kilometers from the distributor home were …