Engine Assembly

Engine Installation

11/3/13 - Attached the engine mounting bracket to the firewall with appropriate bolts, washers and nuts. Torqued the bolts to 24 lb. ft. Total Time = 1 hour. 



Engine Mounts Torqued to Specifications

11/10/13 - Assembled the engine hoist and used tie-down straps to lift the engine from the mini-pallet. Rolled the engine hoist with engine into place and aligned the engine to the mounting bracket bolt locations. Loosely tightened the engine to the engine mount with rubber dampers, large area washers, small washers and nylon locking nuts. Total Time = 4 hours.



Engine Hoisted Into Place

Now the Real Fun Begins

11/15/13 - Mounted the Cabin Heater to the inside of the Firewall Rear Reinforcement using the supplied through bolts from the heater assembly. Total Time = 3 hours.


Cabin Heater Mounted

11/17/13 - Installed the High Pressure Fuel Filter to the engine side of the firewall on the pilot side. Fabricated the Lower Battery Tray from "L" angle and riveted it to the firewall on the passenger side. Drilled holes and mounted the battery "L" brackets for the upper battery position. Total Time = 4 hours.



Battery Tray Fabricated

11/26/13 - Torqued the engine mounting bolts to 24 lb. ft. and paint marked the bolt heads to detect any movement at later inspection intervals.Mounted the crankcase vapor collection canister and the contactor for battery# 1 on the firewall. Total Time = 4 hours.

Engine Mounting Bolts Torqued to Specifications

Oil Vapor Collection Canister

11/30/13 - Mounted the 50 amp fuse and the contactor for battery# 2 on the firewall. Mounted the ground bus on the firewall. Cut a hole on the pilot side of the firewall for the ECM connector and the MAP hoses to fit through. Total Time = 5 hours.

50 Amp Fuse and Battery Contactor for Battery# 2 Mounted

Cutout for the ECM Hoses and Connector

12/1/13 - Located the Header Tank in the cabin area in front of the passenger seat. Marked and drilled a hole in the floor for the drain plug to fit through. Also drilled holes in the Seat Channel for the Header Tank fittings to fit through. Total Time = 4 hours.

Holes Drilled for the Header Tank Fittings

12/4/13 - Fabricated Header Tank brackets to hold the Header Tank in place. Drilled holes in the floor and fitted the header tank brackets in place. Total Time = 3 hours.


Header Tank Brackets Fabricated

12/15/13 - Located the position of the Fuel Pump Assembly under the passenger seat pan. Drilled a hole in the Right Arm Rest for the supply fuel line to pass through. Drilled holes in the floor for mounting the Fuel Pump Assembly. Riveted nut plates to the underside of the floor and fastened the Fuel Pump Assembly to the floor. Total Time = 5 hours.


Fuel Pump Assembly Mounted to Floor

12/23/13 - Drilled a hole in the floor for the Fuel Pass-Through fitting. Mounted the fitting and the elbow with barbed fitting on the top and bottom of the floor. Total Time = 2 hours.

Fuel Pass-Through Fitting Mounted

12/27/13 - Mounted the Fuel Flow Meter and the fuel line from the fuel filter to the fuel rail with Oetiker clamps. Secured the fuel line with an Adel clamp attached to the firewall rail. Total Time = 3 hours.


Attaching the Fuel Line to the Fuel Rail with an Oetiker clamp

12/30/13 - Mounted the fuel line from the Fuel Pass-through under the floor to the High Pressure Fuel Filter on the Firewall using Adel Clamps. Total Time = 3 hours.


Fuel Line Run Underneath the Floor

Fuel Line Attached to High Pressure Fuel Filter

3/22/14 - After a long delay due to a very cold winter I was back at work in the garage. Drilled pass-through holes into the Seat Channel for the 9/16 inch fuel supply hoses from the wing tanks. Installed rubber grommets into the pass-through holes. Installed a fire sleeve over the fuel line from the fuel rail to the lower fuel tray. Total Time = 7 hours.

Pass-Through Holes Drilled with Rubber Grommets Installed

Fire Sleeve Installed Over High Pressure Fuel Line

3/23/14 - Installed Adel hose clamps on the fuel line to secure fuel hose in place. Cut 2 pieces of wire loom and installed on fuel hose to protect the fuel line from chaffing in the lower fuel tray. Installed the Oil Mist Tube from the Crankcase Breather Filter to the collection bottle. Also installed the Aluminum Condensation Versatube for the oil mist to collect and exit the lower part of the cowling area. Total Time = 4 hours.

Wire Loom Installed Over Fuel Line to Protect Against Chaffing

Oil Mist Tube Installed

3/30/14 - Cut fuel hose to the proper lengths and installed on the fuel pumps. Installed the visual indicator on the Header Tank Sight Gauge. Cut a length of "L" Angle and attached to the hose clamps for a hose protector. Total Time = 7 hours.


Fuel Hose Cut to Length and Attached to Fuel Pumps

Fuel Sight Gauge Added to Header Tank

4/6/14 - Fabricated an ECM (Electronic Control Module) bracket out of (2) "L" Angles for the engine computer. Installed brackets on cabin side ribs using rivet nuts. Total Time = 3 hours.

Engine Computer Mounted with "L" Angles

4/12/14 - Installed the heater supply line from the cylinder head area to the input side of the cabin heater using hose clamps and adel clamps to secure hoses.


Supply Heater Line Installed

Installed the heater return line from the coolant tower to the output side of the heater using hose clamps and adel clamps to secure the hoses. 

Heater Return Line Installed

Installed the coolant overflow tank. Installed the the coolant overflow tube from the overflow tank to the cooling tower. Wrapped the heater hoses wire wire loom to protect them from chaffing. Total Time = 6 hours.

Wire Loom Added to All Heater Hoses to Protect Against Chaffing

4/19/14 - After finding out that no one out there had a dual throttle control for a Viking Zenith 750 I decided to make one myself. I used aluminum cylinder stock and drilled a 10-32 threaded hole in the center of one end and then 2 threaded holes in the other end. I bought a 4 ft. and a 5 ft. A-800 friction lock throttle cable from Aircraft Spruce. I screwed the aluminum cylinder with the hole drilled in the center into the throttle body end. I then threaded both throttles into the other end of the aluminum stock. I used adel clamps to fasten the throttle cables in place so they wouldn't move at the crimped area of the throttle cables. Total Time = 3 hours.



Dual Throttle Attached With a Threaded Aluminum Cylinder

 

Adel Clamps used to Fasten Throttle Cables in Place

 Dual Throttle Actuator Video

Total Engine Installation Time = 71 Hours