Vans Aircraft RV-12 Airplane Build, Section 49: Cooling System (part 5)

Reference for this entry: page 49-04, 49-06, 49-07, 49-10; 3.5 hours

Today's entry is more work on the RV-12 airplanes cooling system. I called Van's Aircraft today because I couldn't find the hoses (H460) by name in the packing slips. As it turns out, it is the same as H173 3/16" fuel line.

Reference: 49-04

Step 4: Use the FF-1206C Hinge Pin to attach the Cooler Box Door Assembly to the FF-1206A Cooler Box Hinge. Safety wire the hinge pin to the FF-1204B Upper Cooler Box Rib. Use the provided safety wire holes in the upper cooler box rib.



This completes page 49-04.

Reference: 49-06

Step 4: Cut a 24 inch long piece of EA HOSE H460 to make the FF-1220 Overflow Bottle Hose.



Step 9: Slip the FF-1220 Overflow Bottle Hose over the stem on the 922 327 Overflow Bottle.



Step 10: Attach the 922 327 Overflow Bottle to the F-1201A Firewall Upper using the F-1201V Coolant Bottle Strap and hardware called out.



This completes page: 49-06

Reference: Page 49-07

Step 1: Slide the free end of the F-1220 Overflow Bottle Hose over the barbed stem on the 922 665 Expansion Tank Assembly.



Step 2: Route the F-1220 Overflow Bottle Hose using tie-wraps.



Reference: Page 49-10

Step 5: Insert the bent end of the CT A-740 BLACK Push Pull Cable wire into the FF-1210 Cable End.



Step 6: Insert the cotter pin through the hole in the FF-1210 Cable End with the eyelet facing the side of the cable end (as shown in Figure 3 page 49-06). Rotate the cotter pin 90 degrees then bend the legs of the cotter pin around the cable end.

Step 7: Screw the jam nut onto the rod end as shown in Figure 3. Screw the rod end all the way into the FF-1210 Cable End until it bottoms out on the CT A-740 BLACK Push Pull Cable wire. Tighten the jam nut against the cable end.

Step 8: Using the hardware called out in Figure 3 attach the rod end to the FF-1205B Cooler Box Bracket.



Step 9: Verify proper operation of the Cooler Box Door Assembly. If needed, loosen the clamps and reposition the CT A-740 BLACK Push Pull Cable so that the cooler box door assembly closes tightly leaving a 1/16 gap between the knob and the F-1201A-1 Instrument Panel. When satisfied safety wire the push pull cable to the cushioned clamp as shown in Figure 3 on page 49-06.



This completes page 49-10 and this entry.

Vans Aircraft RV-12 Airplane Build, Section 49: Cooling System (part 4)

Reference for this entry: page 49-06, 49-11; 3.5 hours

Step 1: Install the Oil Tank Assembly using two band clamps as shown in Figure 1. Trim bolts on clamps if desired leaving a minimum 1/4 inch of exposed threads.



Step 2: Cut a 1 1/2 inch long piece of EA H177 Hose to make the FF-1219 Oil Vent Interconnect.



Step 3: Cut a 28 inch long piece of .062X3/8 104-0375062 Tube to make the FF-1218 Oil Tank Vent Tube.



Step 5: Slip the FF-1219 Oil Vent Interconnect onto the barbed stem on the Oil Tank Assembly. Insert the FF-1218 Oil Tank Vent Tube into the oil vent interconnect.



Step 6: Remove the right bolt and washer attaching the GAS-5 Gascolator, slip a cushioned clamp over the bolt, slide the FF-1218 Oil Tank Vent Tube through the cushioned clamp then reinstall the bolt.



Step 7: Bend the FF-1218 Oil Tank Vent Tube below the cushioned clamp attached to the GAS-5 Gascolator as necessary to clear the flange in the F-1201C Firewall Bottom.



Step 8: Hold the 922 327 Overflow Bottle in the installed position as shown in Figure 1. Note the face that will lay against the F-1201A Firewall Upper. Smear a thin layer of RTV over the two ridges on this face of the overflow bottle to prevent them from chafing against the firewall upper.



Builder's note: I used wax paper to get a nice finish.



Reference: Page 49-11

Step 1: Deburr the edges of the FF-1212 Oil Cooler Frame, FF-1213 Oil Cooler Frame Bottom and the FF-1214 Oil Cooler Faceplate.



Step 2: Machine countersink the #40 holes on the side flanges of the FF-1214 Oil Cooler Faceplate flush on the inside face. Dimple the corresponding holes in the FF-1212 Oil Cooler Frame flush on the inside face.



Step 3: Dimple the holes in each FF-1215 Oil Cooler Spacer flush on one side. See Figure 1. Dimple the corresponding holes in the FF-1212 Oil Cooler Frame flush on the inside face.



Step 4: Machine countersink all the #40 holes in the forward face of the FF-1214 Oil Cooler Faceplate flush on the forward side.



This complete's today's work on the airplane.

Vans Aircraft RV-12 Airplane Build, Section 49: Cooling System (part 3)

Reference for this entry: page 49-04, 49-08, 49-09, 49-10; 6.0 hours

Today's contains with work on the RV-12 airplane's engine cooling system. I am adding a Builder's Gotcha only because it took three attempts to form a gasket on the Cooler Box Door. (some of us are slow learners;) I also a m jumping over the installation of the radiator until after the heater door control is completed. Because I can't see having to work around the hoses and radiator to install the control.

Step 1: Rivet the FF-1204A Cooler Box Face and FF-1206A Cooler Box Hinge to the F-1201C Firewall Bottom using the rivets called out by Van's Aircraft. Rivet the remaining holes common between the cooler box face and the firewall bottom.



Step 2: Rivet the FF-1204B Upper Cooler Box Rib and FF-1204C Lower Cooler Box Rib to the F-1201C Firewall Bottom using the call-outs in Figure 1.



Step 3: Rivet the FF-1204A Cooler Box Face to the FF-1204B Upper Cooler Box Rib and FF-1204C Lower Cooler Box Rib using the call-outs in Figure 1.





Step 4: Use the FF-1206C Hinge Pin to attach the Cooler Box Door Assembly to the FF-1206A Cooler Box Hinge. Safety wire the hinge pin to the FF-1204B Upper Cooler Box Rib. Use the provided safety wire holes in the upper cooler box rib.

Builder's note: This was not done until after the cooler door control was finished on 6/24/14.

Step 5: Cover the F-1201C Firewall Bottom with wax beneath the Cooler Box Door Assembly.

Builder's note: OK this is the GOTCHA. I tried packing tape, I tried PVA and then I final tried wax paper. The wax paper worked great! As it allowed me to look at the seal quality and RTV flow pattern before the RTV setup. I have included pictures of the failed attempt below for entertainment and education.

Step 6: Scour the aft face of the FF-1205 Cooler Box Door with Scotch Brite around the edge where the RTV gasket is depicted in Figure 2 on page 49-04.



Step 7: Add a bead of high temp RTV around the edge of the FF-1205 Cooler Box Door as shown in Figure 2 then close the Cooler Box Door Assembly firmly agains the firewall. Temporarily hold the door closed with tape from the end of the FF-1205B Cooler Box Bracket to the edge of the fuselage.















Builder's note: Here are some of the bad attempt below.





Reference: Page 49-08

Step 1: Modify a grommet to be used for firewall penetration. Using a socket and a vise, squeeze the grommet called out in Figure 1 in page 49-08, until the socket shears through the grommet (this will be accompanied by a distinct crunching sound).



Step 2: Install the firewall grommet from Step 1 into the control cable penetration location in the F-1201A Firewall Upper.



Step 3: Install the CT A-740 BLACK Push Pull Cable into the F-1202A Instrument Panel and through the firewall grommet installed in Step 2.

Builder's note: I had to chamfer the hole to get the control cable to set flush with the panel.





Step 4: Install a cushioned clamp on the F-1202B Panel Base to support the CT A-740 BLACK Push Pull Cable.



This completes page 49-08

Reference: 49-09

Step 1: Add three sets of cushioned clamps to the WD-1220 Engine Mount Ring routing the CT A-740 BLACK Push Pull Cable through each.



Step 2: Install the friction Comb between the lower set of cushion clamps.



Step 3: Pull the handle and attached wire of the CT A-740 BLACK Push Pull Cable completely out of the cable sheath.



Step 4: Using the dimensions in Figure 1 on page 49-09, trim the CT A-740 BLACK Push Pull Cable sheath.

This completes page 49-09.

Reference: Page 49-10

Step 1: Reinsert the CT A-740 BLACK Push Pull Cable into its sheath. Close the Cooler Box Door Assembly.

Step 2: Screw the jam nut all the way onto the rod end then screw the rod end all the way into the FF-1210 Cable End as shown in Figure 1. Using the bolt called out in Figure 1 temporarily attach the rod end to the FF-1205B Cooler Box Bracket.



Step 3: Push the CT A-740 BLACK Push Pull Cable wire in, leaving a 1/16 gap between the knob and the F-1202A Instrument Panel. Mark the location of the hole in the FF-1210 Cable End on the wire. Disassemble the rod end, nut and cable end from the FF-1205B Cooler Box Bracket.




This completes this work session on the RV-12 airplane.

Vans Aircraft RV-12 Airplane Build, Section 49: Cooling System (part 2)

Reference for this entry: page 49-02, 49-03; 4.5 hours

So today start the Cooling system for the RV-12 in ernest.

NOTE: Save excess EA HOSE H151 material for use in Section 50.

Step 1: Cut two lengths of EA HOSE H151 per the dimensions given in Figure 1 on page 49-02 to make the FF-1208A Radiator Hose - Input and FF-1208B Radiator Hose - Output.



Step 2: Deburr the ends of the FF-1208C Expansion Springs.



Step 3: Insert a FF-1208C Expansion Spring inside of the FF-1208A Radiator Hose - Input and FF-1208B Radiator Hose - Output in the location called out in Figure 1. Grab the end of the spring with pliers and twist spring to reduce its outside diameter if necessary.

Builder's note: The spring that shorter of the two hoses appears to be longer than the hose. Not sure why if it becomes an issue I will document it in an upcoming blog entry.



Step 4: Make the FF-1206A and FF-1206B Cooler Box Hinges from MS20257C4-4 Stainless Steel Hinge using the dimensions given in Figure 2 in the RV 12 plans page 49-02.

Step 5: Make the FF-1206C Hinge Pin from SSP-120 Stainless Steel Hinge Pin.



This completes page 49-02.

Reference: 49-03

Step 1: Align the FF-1206B Cooler Box Hinge with the FF-1205 Cooler Box Door as shown in Figure 1. Match-Drill #40 the holes in the cooler box door into the cooler box hinge. Cleco as you drill.



Step 2: Disassemble the FF-1206B Cooler Box Hinge from the FF-1205 Cooler Box Door. Deburr the cooler box hinge.

Step 3: Dimple all the #40 holes in the FF-1205 Cooler Box Door per the rivet call-outs in Figure 1.



Step 4: Machine countersink the #40 holes in the FF-1206B Cooler Box Hinge and FF-1205B Cooler Box Bracket for the dimples in the FF-1205 Cooler Box Door.



Step 5: Rivet the FF-1206B Cooler Box Hinge to the FF-1205 Cooler Box Door.



Step 6: Rivet the FF-1205B Cooler Box Bracket to the FF-1205 Cooler Box Door per the call-outs in Figure 1. This will complete the Cooler Box Door Assembly.



Step 7: Align then clamp in place the FF-1206A Cooler Box Hinge with the FF-1204A Cooler Box Face as shown in Figure 2. Match-Drill #30 the holes in the cooler box face into the cooler box hinge. Cleco as you drill.



Step 8: Disassemble the FF-1206A Cooler Box Hinge from the FF-1204A Cooler Box Face. Deburr the cooler box hinge.

This completes page 49-03 and this entry in the RV-12 airplane build blog.