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.
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