Baffling: To make sure all the air coming into the radiator opening on the cowl actually enters the radiator, we needed to create a baffle seal between the coolant radiator and the cowl. The radiator provided by Rotax did not have any means to attach a baffle so an aluminum surround was fashioned out of 0.032 aluminum. It was secured at the four mounting positions of the radiator. Silicone baffle material was at attached with rivets and rivet washers. The cowl was installed and the baffle material was marked so that it could be trimmed to fit.
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| Radiator surround and attached silicone baffle material |
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| Side seal of baffle to cowl |
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| Bottom Seal of Baffle to cowl |
The shape of the oil door was tweaked a bit to match the curve of the cowling. The hinge pin and spring on the oil door were then installed.
Fuel filter placement was adjusted slightly to improve clearance from the boot cowling.
Baggage Floor: Two separate thin (0.02") aluminum sheets that formed the baggage floor needed to be modified due to other changes that occurred during fabric covering and fuel routing. Some of the edges were trimmed to prevent interference with the fabric, a hole for the fuel drain was enlarged. Also, another hole in the floor (no longer needed due to a change in our fuel routing), was patched.
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| Rear baggage floor with riveted patch and larger hole for drain |
Clamps: Four standard Adel clamps (black) were replaced with silicone clamps (blue). They have a higher temperature rating, but are also the better choice for holding the silicone hoses that they are clamping. Hours: 15
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| Blue silicone clamp now holds this silicone hose |
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