Revision List - Lancair Documents

Baffling – Kit LES-550-BF (Continued) Item Part Number QTY Description 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.3 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 35) BF-MT-3 20 ft. Baffling Seal, 3” wide, orange 36) 05-16100 1 Terminal Bolt Kit 3/16” drilled shank 37) AD42ABSLF 120 Rivets - pop 1/8” alum. large head 38) AN3-3A 70 Bolt - undrilled 10-32 x 15/32 x 1/16 39) AN363-1032 10 Locknut, steel, hi-temp 10-32 40) AN364-832A 1 Nut - elastic stop 8-32 41) AN426A3-4 170 Rivets - soft 3/32 x 1/4 42) AN426AD3-8 6 Rivets - hard 100 3/32 x 1/2 43) AN500-A416-6 8 Screw - fillister head 44) AN742D4 1 Clamp - loop plain 1/4 tube O.D. 45) AN960-08L 1 Washer 8, thin, flat 46) AN960-10 55 Washer - flat 3/16 (.203) 47) AN960-10L 20 Washer - thin, flat 3/16 48) AN960-616 1 Washer - flat 3/8 (.390) 49) BSPQ-44 20 Rivets - pop 1/8 x .250 50) K1000-3 60 Nutplate/anchor - two lug metal 10-32 51) MS20001 3 Hinge - continuous aluminum (piano hinge) 52) MS20074-06-05 1 Bolt - coarse thread 3/8-16 53) MS35333-38 1 Washer - star internal teeth #8 54) MS35338-44 6 Washer - split helical lock 1/4 55) MS35489-18 3 Grommet - syn/rubber 5/8 x 1-1/2 x 1-1/2 x 1/4 56) MS35649-202 2 Nut - plain hexagon 57) RC1023 1 Grommet - linear 58) SCAT-4 5 ft. Tubing - SCAT 1.0” I.D. 59) SCAT-6 2.5 ft. Tubing - SCAT 1.5” I.D. Baffling – Kit LES-550-BF (Continued) Item Part Number QTY Description Fuel Pump– Kit 518-IO550 Item Part Number QTY Description 1) 518-02 1 Fuel pump shield 2) 518-03 1 Stub for fuel pump shield 3) 145-0004 5416K15 2 Clamp - hose 13/16” to 1-1/2” 4) 561-1 1 Flange tube aluminum 1” scat 5) AN364-832A 1 Locknut, elastic stop 8-32 6) AN960-8L 2 Washer - #8 thin, flat 7) MS21042-08 2 Nut - all metal stop 8-32 8) MS35333-38 1 Washer - star internal teeth #8 9) MSC-32 3 Pop rivets 10) Scat-4 2 Scat tubing 1” I.D. Engine Control Systems – Cable-IO550 Item Part Number QTY Description 1) 31509 3 Clamp - engine mount control cable 2) 565-02 1 Bracket - mixture control cable 3) 106-0016 91150A114 2 Washer - locking 3/8 zinc 4) 103-0026 91811A031 1 Nut - 3/8-24 coupling 5) A750-BU-5 5 ft. Cable - propeller control (blue) 6) A750-RD-5 5 ft. Cable - mixture (red) 7) A800-BK-5 5 ft. Cable - throttle (black) 8) AN3-10A 1 Bolt - 10-32 x 5/8 9) AN3-11A 2 Bolt - 10-32 x 1 x 1/8 undrilled 10) AN315-3 3 Checknut 11) AN3-3A 2 Bolt - 10-32 x 15/32 x 1/16 12) AN3-4A 2 Bolt - 10-32 x 17/32 x 1/8 13) AN3-7A 2 Bolt - 10-32 x 29/32 x 1/2 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.4 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 14) AN315-3 3 Nut - full hex 10-32 thread 15) AN363-1032 10 Nut - steel stop hi-temp 10-32 16) AN6-5A 1 Bolt - 3/8-24 x 45/64L 17) AN960-10 19 Washer - flat 3/16 (.203) 18) AN960-10L 2 Washer - flat, thin 3/16 19) AN960-616 1 Washer - flat 3/8 (.390) 20) AN970-3 3 Washer - flat 3/16 x .875 21) AN970-6 2 Washer - flat 3/8 x 1/625 22) HFC-3 3 Bearing - rod end throttle cable 23) PG564 1 Bracket - prop governor cable 24) SP565 1 Spacer - engine mount control cables 25) TB563 1 Bracket - throttle cable 26) MS35489-11 3 Grommet - syn/rubber, 3/8 x 7/8 x 5/8 x 5/16 Manifold Pressure and Tachometer Item Part Number QTY Description 1) C5205x4x4 1 Fitting 2) MS27404-4D 2 Fitting 3) 193-4 1 Hose Gascolator Item Part Number QTY Description 1) GAS-500F-BYP 504 1 Gascolator 2) 504-06 1 Attach Bracket 3) 504-07 1 Gascolator Shroud 4) 145-0003 5416K14 2 Clamp - hose 1.0” Engine Control Systems – Cable-IO550 (Continued) Item Part Number QTY Description 5) AN3-3A 3 Bolt - 10-32 x 15/32 x 1/16 6) AN3H11A 4 Bolts 7) AN426A3-5 6 Rivets 8) AN960-10 10 Washer - flat 3/16 (.203) 9) C5205x8x8 2 Fitting adapter male 1/2 - 1/2 10) K1000-3 3 Nutplates 11) SCAT-4 2 ft. Tubing SCAT 1.0” 12) 2240-4-8S 1 Bulkhead Flare Fitting - gascolator to firewall Fuel Systems Item Part Number QTY Description 1) 4890 28” Fuel Supply Line 2) AN912-1D 1 Bushing Reducer 3) 145-0003 5416K14 2 Clamp - hose 4) MS21919-DG32 2 Clamp 5) MS21919-DG10 2 Clamp 6) AN624-4D 1 Fitting - T 7) AN816-4-4 2 Fitting 8) AN822-4D 1 Fitting - elbow 9) AN822-4 1 Fitting - elbow 10) 2240-6-8S 1 Fitting - bulkhead 11) 561-1 1 Flange - inlet 12) 510A 4 Fuel Return Line 13) 193-4 7’ Fuel distributor Drain Line 14) 530 21” Fuel Line 15) A500 1 Andair Gascolator 16) MS35489-13 1 Grommet Gascolator (Continued) Item Part Number QTY Description 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.5 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 17) AN931-12-23 1 Grommet 18) 514 1 Hose - prebuilt 19) 515 1 Hose - prebuilt 20) 516 1 Hose - prebuilt 21) K3000-3 3 Nutplate 22) AN913-ID 1 Plug 23) MSC-32 4 Rivets - pop 24) AN426A3-4 6 Rivets 25) SCAT4 1 Tubing - flexible 26) AN960-6D 1 Washer 27) 145-0000 5321K14 Drain line clamps Oil Systems Item Part Number QTY Description 1) 165-0000 8500K83 1 Anti-chafe Material 2) AN3-7A 1 Bolt - undrilled 3) MS21919-DG16 1 Clamp 4) 145-0003 5416K14 1 Clamp 5) AN912-3 1 Coupling - steel 6) HK822-4 1 Fitting (with .05” restriction) 7) AN363-1032A 1 Locknut - nylon 8) 124F001-4CR0160 16” Oil Pressure Line 9) MIL-H-6000x3/4 1 Oil Breather Line 10) AN960-10 1 Washer - flat Fuel Systems (Continued) Item Part Number QTY Description Propeller/Spinner – Kit SP-ASSY-550 Item Part Number QTY Description 1) 1026B-12-12 1 Prepreg - 2 ply 1/4” +45 12x12 2) 1054-1 1 Spinner 3) 1054-2 1 Plate Spinner Backup 4) AN426A3-5 50 Rivet - soft 100DEG 3/32 x 5/16 5) AN526-1032-R10 18 Screw - truss head 10/32 x 5/8 6) AN960-10L 18 Washer - flat thin 3/16 7) K1000-06 6 Nut - anchor two lug metal 6-32 8) K1000-3 18 Nut - anchor two lug metal 10-32 9) MS24693-S28 6 Screw - flat 6-32 x1/2 10) PHC-J3YF-1RF/F7693DF 1 78” Diameter 3-bladed Hartzell Propeller Cowling Item Part Number QTY Description 1) 2000B 1 Bottom cowl 2) 2000T 1 Top cowl 3) H-5000-2 1 Hartwell flush steel latch 4) MS2001 1 Hinge 5) MS24694-S5 100 Screw - flat 8-32 x 17/32 countersunk 6) MSC-34 50 Rivets 7) K1000-08 50 Nutplates 8) 802-0001 1 Oil door remote latch kit Latch cable Air Induction – Kit 4867-A Item Part Number QTY Description 1) 4867 1 Air induction tube - IO550 2) 4867-01 1 Lever arm 3/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.6 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 3) 4869 1 Hose coupler for air filter 4) 4873 1 Bracket for attaching cable 5) 4874 1 Control cable, 6’ with push button 6) 4878 1 Spacer 7) 145-0009 5416K25 2 Clamp - Hose 3” O.D. 8) 101-0060 91251A153 1 Screw - socket head 6-32 x 1 9) AN3-4A 2 Bolt 10-32 x 17/32 x 1/8 10) AN363-1032 2 Nut - steel stop Hi-temp 10-32 11) AN363-524 2 Nut - steel all metal 5/16-24 12) AN3-6A 1 Bolt 10-32 x 25/32 x 3/8 13) AN3-7A 1 Bolt 10-32 x 29/32 x 1/2 14) AN5-16A 1 Bolt - 5/16-24 x 1 x 3/8 15) AN5-6A 1 Bolt - 5/16-24 x 27/32 x 3/16 16) AN960-10 4 Washer - flat 3/16 (.203) 17) AN960-10L 7 Washer - flat, thin 3/16 18) AN960-516 3 Washer - flat 5/16 (.328) 19) AN960-6 1 Washer - flat #6 (.149) 20) HFC-3AU) 1 Bearing rod end - throttle cable 21) MS21042-06 1 Nut - all metal stop 6-32 22) MS21042-3 2 Nut - all metal stop 10-32 23) MS21919-DG3 1 Clamp - Adel 3/16 cushioned 24) MS35489-6 2 Grommet - syn/rubber 1/4 x 5/8 x 7/16 x 3/16 25) RC2600 1 Air filter, high-flow cone type 26) SHC-1010 1 Connector .25-.31 cord dia. 3/8 27) SHC316-22-002 1 Locknut 3/8 NPT cord connector Air Induction – Kit 4867-A (Continued) Item Part Number QTY Description Vacuum System – Kit LES-550-VC (optional) Item Part Number LES-550-VC QTY Description 1) 1058 1 Shroud vacuum pump cooling 2) 193-10 2 Hose - low pressure 5/8” I.D. 3) 193-4 3 Hose - low pressure 1/4” I.D. 4) 193-6 7 Hose - low pressure 3/8” I.D. 5) 1J7-1 1 Vacuum Pump Filter 6) 1K1-6-10 1 Fitting - Airborne 90 7) 1K8-6-10 1 Fitting - Airborne 135 8) 216CW 1 Pump vacuum 9) 2H3-12 1 Regulator for vacuum system 10) 145-0001 5321K16 10 Clamps - hose 1/2” O.D. 11) 145-0003 5416K14 2 Clamps - hose 1” O.D. 12) AN840-4D 1 Hose nipple fitting 1/4-1/8 13) AN840-6D 4 Hose nipple fitting 3/8-1/4 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.7 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Figure 26.2.0.1 Forward side of the firewall with mounting locations, openings and dimensions 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.8 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3 Construction Procedures 26.3.A Mounting the Engine The Continental IO-550N can use either of the following two types of engine mount isolators. • J-9613-54 provided by Lord • 94001-01 High Temp provided by Barry (recommended) • 94011-20 Low Temp provided by Barry Each type of engine mount isolators consists of three pieces, a thinner isolator, a sleeve and a thicker isolator. Review Figure 26.3.A.1 to verify the installation location of each piece: • Thin isolator is placed on the top (engine side) of the mount, • Thick isolator is placed on the bottom (away from the engine) of the mount. Steps... 1. Position each of the four top vibration isolators on the four engine mount pads. 2. Gently ease the engine into place using a suitable hoist. Check with your local FBO to find out if you can borrow an engine hoist. AN970-7 AN7-33A 98-9074-11 588-02 Figure 26.3.A.1 Installing the engine mounts and engine 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.9 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 3. As the front engine brackets make contact, hold some of the weight off while you install the remaining pieces: the sleeve, the thicker isolator and the washer (98-9074-11 AN970-7) and the bolt (AN7-33A). Tip: Aligning the engine bracket to the mount pads may require some wiggling. 4. Continue by completing the installation of the aft engine mounts. 5. Torque the AN7-33A bolts to 400 in-lbs (35 ft.-lbs.). WARNING: Do NOT forget the sleeves in the isolator assemblies! This completes the engine mounting. Figure 26.3.A.2 Review this photo of the Isolator placement and assembly Vibration Isolator (high temp.) 94001-01 (recommended) Washer, 98-9074-11 (for vibration isolator) Bolt, AN7-33A Safety wire attach, 588-02 3/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.10 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3.B Installing the Engine Exhaust The custom exhaust system (EX-6) for the Lancair ES, with the IO-550N engine, is available through Lancair. All the hardware for mounting the exhaust is included with the exhaust system. Steps... 1. Remove the plastic exhaust exit covers from underneath the cylinders. Caution: Excess oil may spill out when you remove the exhaust exit covers. 2. Mount the upper pieces of the exhaust on both the left and right sides of the engine using the nuts and gaskets that came with the engine (only with new engines). See Figure 26.3.B.2 Mounting the upper exhaust on the next page. 3. Mount the lower pieces of the exhaust using the hardware supplied with the engine exhaust kit. Make sure the pipes are even. See Figure 26.3.B.3 on the next page. 4. Install the heat muff on the left exhaust. 5. Secure the lower portion of the exhaust to the firewall. Use the provided strap that came with the engine exhaust kit. Figure 26.3.B.1 Engine exhaust Engine exhaust Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.11 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Figure 26.3.B.2 Mounting the upper exhaust EX-6 Figure 26.3.B.3 Securing the lower exhaust piece to the firewall Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.12 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3.C Installing the Baffling The Lancair baffling kit (LES-550-BF)for the Continental IO-550N engine includes all the pieces required to install the baffling. For a complete list of the ES baffling kit see the table on page 26.2. The baffling is designed to allow for easy installation and removal. Almost any part of the baffling can be removed without having to remove another piece. As you unpack the baffling kit, the baffling appears to be a lot of odd pieces of aluminum. If you systematically assemble the baffling it is not too difficult to install. Some trimming of the pieces is required. Factory installed baffling The new factory Continental IO-550N engine comes with pre-installed center and lower cylinder baffles. These baffle parts are essential for proper engine cooling. If you do not have a new factory engine, refer to 26.3.L Factory Installed Baffling on page 26.52 for information on installing these specific pieces. Installation order Although the baffling can be installed in any order, we suggest you follow the same order we use in this manual. The following pieces are contained in the baffling kit but are not displayed in any of the illustrations. FM-567-057 3568-029 3568-028 3568-038 FM-567-063 FM-567-058 3568-010 FM-567-064 3568-014 4851-018 3568-011 3568-040 3568-007 4851-023 3568-031 3568-006 4851-016 4851-024 3568-030 3568-003 4851-027 4851-026 3568-023 3568-001 3568-000 4851-035 3568-002 4851-025 Part Number QTY Description 3568-041 6 EGT support brackets 3568-042 2 Drain line support brackets 3568-043 4 Oil line support brackets 3568-044 4 Oil line support brackets3 Figure 26.3.C.1 Baffling layout – overview Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.13 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Figure 26.3.C.2 provides a detail view of the complete baffling layout as seen in the baffling overview on the previous page. The subsequent pages in this section provide a breakdown down of this figure into piece by piece assembly, in the order we suggest you use for installing the baffling. Let’s start by removing the baffling kit pieces from the box and arranging the pieces on your work surface. Fitting the baffling When installing the baffling it is particularly important to understand how the pieces fit together. The following fits are important. • Oil cooler box fit – The oil cooler box (FM-567-064) fit needs to be checked to the left wing (3568-010) and the rear left vertical panel (FM-567-058). • Oil cooler door fit – The oil cooler door (3568-014) needs to seal snugly against the rear left vertical panel (FM-567-058). • Front shrouds – Rivets on the front outer edge of the two front shrouds must be at least 3/4” from the edge. This 3/ 4” is the amount of required space for securing the baffling seal. • Baffling seal – The baffling seal pieces must lay inward against the cowling top to form a good seal that tightens when pressurized with ram air. If a flexible baffle were to get blown back, a massive air leak would result and the engine could easily overheat. We recommend that you clamp each piece in place and verify the fit before drilling the bolt or rivet holes. Pre-fit the baffle panels to the engine. Then fit the cowling to check the cowling clearance to the engine baffles. Don’t use the baffling seal for this pre-fit. Footnotes 1. 567-038 Light starter Figure 26.3.C.2 Baffling layout – detail view FM-567-063 FM567-058 3568-014 3568-010 3568-0006 3568-023 3568-002 4851-025 4851-035 4851-035 4851-016 4851-036 4851-011 3568-001 FM-567- 064 3568-031 3568-000 4851-026 4851-027 3568-003 4851-024 3568-030 3568-040 4851-023 3568-040 3568-007 3568-011 4851-018 FM-567-057 3568-029 3568-028 3568-038 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.14 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Oil Cooler Box When installing the oil cooler baffling it is particularly important to understand how the pieces fit together. A good fit is critical to achieve proper cooling. See Fitting the baffling on page 26.13 for details. Steps... 1. Fit the oil cooler box (FM-567-064) between the oil cooler and aft of cylinder 2. 2. Align the oil cooler box to its proper location and hold it in place. 3. Mark a hole on the oil cooler box for securing the box to the engine tab. Do this by holding the top of a felt pen and marking the oil cooler box at the location where the engine tab and the oil cooler box will be bolted together. Tip: The horizontal engine tab needs to be on top of the oil cooler box baffling. 4. Remove the oil cooler box and drill a 3/16” diameter hole in the oil cooler box. 5. Install the nutplate as shown in the magnified illustration. Tip: Due to slight variations of each engine, it may be necessary to file certain areas. 6. Align the L (oil cooler) bracket (FM-567-063) against the oil cooler. Install the left side using the K1000-3 nutplates (4 pcs) and the AN426A3-5 rivets (8 pcs) as shown in Figure 26.3.C.6. 7. Now install the rear left vertical panel (FM-567-058) on the front face of the oil cooler. Position the rear left panel as shown in Figure 26.3.C.11. The top cable bracket holes should align with the rear left vertical panel and the oil cooler. Use three AN3-5A bolts with the with the AN960-10 washers and the locknut, AN363-1032 to assemble the three pieces. Figure 26.3.C.3 Oil cooler box install 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.15 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Oil Cooler Door Before you proceed, check the fit of the oil cooler door. It needs to seal snugly against the rear left vertical panel. Steps... 1. Drill four holes on the front of the oil cooler box. 2. Insert four panhead screws (AN525-10R6). 3. Referring to the detail view below, see circle A for the fit of the installed oil cooler door (3568-014). 4. Insert the piano hinge and again test the fit of the oil cooler door. 5. Trim off the lower edge of the door to achieve a good fit. See circle B in the figure below. Figure 26.3.C.4 Side view of the oil cooler box with door 6. Now safety wire (not supplied, builder must provide) the piano hinge pin. Review this photo of the hinge for the oil cooler door. Figure 26.3.C.5 Oil cooler door MS20001 FM-567-064 FM-567-058 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.16 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Completing the Oil Cooler Box Installation Steps... 1. Align the lower oil cooler box baffle (3568-031) with the cylinder fins. 2. Install the lower oil cooler box baffle using pop rivets and washers. Refer to the detail view Figure 26.3.C.10 for positioning. 3. Install the terminal bolt kit (05-16100) on the oil cooler door (3568-014). The assembled terminal bolt kit must rotate freely. 4. Secure the end of the cable to the oil cooler door. This cable will run from the oil cooler door to the instrument panel. You will finish the cable installation along with the remaining pieces of the rear panel on page 26.20. 4851-023 FM-567-064 FM-567-063 Figure 26.3.C.6 Oil cooler box Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.17 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 5. Position the left rear inner baffle (4851-023) against the oil cooler box and snugly against the cylinder. Secure the left rear inner baffle using two AN3-3A bolts and AN960-10 flat washers. Refer to the detail views on page 26.19 for positioning. Figure 26.3.C.7 Oil cooler door and box installed with baffling Rear left vertical baffle, FM-567-057 Left wing baffle 3568-014 Oil cooler door 3568-014 Piano hinge MS20001 Oil cooler box FM-567-064 Small hole for safety wiring the piano hinge. Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.18 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Figure 26.3.C.8 below is a top view of the oil cooler and the oil cooler door you just installed. The two magnifiers represent the position of the next baffling pieces in the two detail view illustrations, Figure 26.3.C.9 on the right side of this page and Figure 26.3.C.10 on the next page. The first of these baffling pieces attaches to the bottom of the oil cooler box. It is the lower cooler box baffle (3568-031). Figure 26.3.C.8 Oil cooler top view 6. Position the lower cooler box baffle against the bottom of the oil cooler box and snugged to the cylinder. Make sure it lines up with the cylinder fins. Install the lower cooler box baffle using two bolts (AN3-4A) and washers (AN960-10L). 3568-014 FM-567-058 FM-567-064 Figure 26.3.C.9 Detail view – baffle 3568-031 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.19 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES The second of these baffling pieces attaches to the forward surface of the oil cooler box. It is the left rear inner baffle (4851-023). 7. Next position the left rear inner baffle against the oil cooler box and snugly against the cylinder. Secure the left rear inner baffle using two bolts (AN3-4A) bolts and flat washers (AN960-10L). 3568-014 FM-567-058 FM-567-064 Figure 26.3.C.10 Detail view – baffle 4851-023 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.20 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Finishing the Rear Vertical Baffling Steps... 1. Position the rear right vertical panel (FM-567-057) with the outer baffle, at the bottom of the piece, fit snugly against cylinder 1. 2. Join the rear right vertical panel to the rear left vertical panel. The rear left vertical panel was installed on page 26.14 with the oil cooler box. 3. Install the left wing baffle (3568-010) by attaching it to the rear left vertical panel. 4. Using a chisel and hammer, dent the Adel clamp. 5. Attach the Adel clamp (AN742-D4) to the L (oil cooler) bracket (FM-567-063) installed on the oil cooler. 6. Slide the dented rod through the Adel clamp This keeps the cable stationary in the Adel clamp. 7. Thread the oil cooler door cable through the slot in the left wing baffle and through the dented rod. When this cable is fully installed it will run from the oil cooler door to the instrument panel. A-740BLO720 3568-038 FM567-058 Figure 26.3.C.11 Rear left vertical panel baffling Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.21 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 8. Position the right rear inner baffle (4851-018) so that it fits snugly against cylinder 1. 9. Secure the right rear inner baffle to the rear right vertical panel with two MS24693-S4 screws. 10. Install the rear center brace (3568-038) to the lower bolt that connects the right rear and left rear vertical baffles. The other end of the rear center brace rests against the inside of the lifting point. It does not need to be secured. 11. Install the right wing baffle (3568-011) to the rear right vertical panel. 12. Install the support bracket (3568-028, supplied with engine) to the case by installing a case bolt (3/8” x 1/2”) with a lock nut. The other end of the bracket rests against the rear right vertical panel. It does not need to be secured. 13. Remove the outboard forward bolt of the starter. Install the support bracket (3568-029) to the starter by re- installing the bolt. (Use support bracket 567-038 for the lightweight starter.) The other end of the bracket rests against the rear right vertical panel. It does not need to be secured. FM-567-058 Figure 26.3.C.12 Right rear vertical panel baffling 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.22 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Figure 26.3.C.13 View of left rear baffling Rear left vertical panel, FM-567-058 Left wing baffle 3568-010 Oil breather line Grommet for distributor drain line Oil cooler bracket (or L bracket) FM-567-063 Oil cooler door cable threads through baffle at this location. Oil cooler Figure 26.3.C.14 View of center and right rear baffling Rear center brace 3568-038 Rear right vertical panel, FM-567-057 Fuel pump flange Rear left vertical panel, FM-567-058 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.23 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Right Deck Baffling Steps... 1. Install three of the six steel deck brackets (3568-040) by attaching one to each cylinder head on the right side. Use three AN500-A416-6 screws and the MS3538-44 lockwashers. Tip: These screw into the threaded hole located between the cylinder head valve covers. The hole in the head is shallow so do NOT use longer screws or bolts. 2. Mount the nutplates (K1000-3) using two rivets (AN526A3-4) per nutplate. 3. If necessary file the three steel deck brackets across their tops so they sit flat and are relatively level. Filing may be necessary to align the deck brackets with each other since the castings can vary slightly. 4. Secure the right deck (3568-007) to the right wing (3568- 011). 5. Attach the right deck to the three steel deck brackets. This completes the right deck baffling installation. Figure 26.3.C.15 Right deck baffling Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.24 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Left Deck Baffling Steps... 1. Install the three remaining steel deck brackets (3568-040) by attaching one to each cylinder head on the left side. Use three AN500-A416-6 screws and the MS3538-44 lockwashers. Tip: These screw into the threaded hole located between the cylinder head valve covers. The hole in the head is shallow so do NOT use longer screws or bolts. 2. Mount the nutplates (K1000-3) using two rivets (AN526A3-4) per nutplate. 3. If necessary file the three steel deck brackets across their tops so they sit flat and are relatively level. Grinding may be necessary to align the deck brackets with each other since the castings can vary slightly. 4. Secure the left deck (3568-006) to the left wing (3568- 010). 5. Attach the left deck to the three steel deck brackets. The left deck’s outboard flange will need to be 1/4” to 1/2” (3 to 6 mm) from the inside of the cowling when the cowling is installed. This completes the left deck baffling installation. Figure 26.3.C.16 -Left deck baffling Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.25 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Front Shroud Baffling This section installs all four main pieces of the front shroud baffling and attaches it to the left and right decks. Steps... 1. Clamp the upper and lower front shroud baffles together with enough over lap to drill holes through both pieces. 2. Position the upper front shroud baffle (3568-001) on the front of the engine and secure it using the bolts from the seal retainer. If you need longer bolts, two 10/24 x .5” bolts are recommended. Check the thread pattern for a match. Tip: Before you drill the holes, check the clearance with the engine block. Use AN960-10L washers underneath the heads. Use Loctite to secure the bolts. 3. Secure the lower front shroud (3568-000) to the upper piece using bolts. Make sure the two inner holes of the seal retailer are lined up with the holes in lower front shroud baffle piece. 4. Install the two center standoffs (3568-011) on the top edge of the upper front shroud. Use five bolts (AN3-4), ten thin washers (AN960-10L) and five nuts (AN363- 1032). Identify the standoffs before you start. The four standoffs have three different shapes. Make sure the two identical standoffs (3568-011) are installed in the two top center locations. 5. Install the two remaining standoffs (3568-036 and 3568- 037). Review Figure 26.3.C.17 for accurate placement of the standoffs. Review this photo for the rear view of the washers and bolts for the standoffs. Figure 26.3.C.17 Front baffles Front upper shroud 3568-001 Front lower shroud 3568-000 Seal retainer bolts and washers Secure the upper and lower front shrouds using the hardware listed below. Bolt, AN3-4A Washer, AN960-10L Locknut, AN363-1032 Standoff 3568-036 Standoff 3568-011 Standoff 3568-037 Standoff 3568-011 Large area washers secure the standoffs. Front upper shroud 3568-001 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.26 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 6. Clamp the right front shroud (3568-003) and the left front shroud (3568-002) in place, attaching them to the front shrouds and the deck pieces that are already installed. 7. Secure the lower front shroud (3568-000) to the right front shroud’s brackets using six bolts (AN3-3A) washers (AN960-10) and heat nuts (AN363-1032). 8. Secure the right deck (3568-007) to the right front shroud’s brackets using bolt (AN3-4A) washers (AN960- 10L) and heat nut (AN363-1032). 9. Repeat these last two steps for the left front shroud. 10. Attach the two brackets (4851-026 and 4851-027) to the right front shroud. 11. Attach the right front outer baffle (3568-030) to the right front shroud. 12. Attach the front right inner baffle (4851-024) to the right front shroud. Tip: The front right inner baffle should fit snugly against the cylinder. 13. On the right front shroud, silicon the provided rubber patch to the seal around the alternator exhaust. Review this photo for the alternator exhaust seal. Figure 26.3.C.18 Front right shroud Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.27 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 14. Attach the two brackets, 3568-023 and 4851-025 to the front left shroud (3568-002). 15. Attach the front left inner baffle (4851-016) to the front left shroud using pop rivets. 16. Attach the left front outer baffle (4851-035) to the front left shroud using pop rivets. 17. Secure the front left shroud to the left deck (3568-006). Tip: The baffling pieces 4851-016 and 4851-035 that are attached to the front left shroud should fit snugly against the cylinder. This completes the front, the front left and the front right shroud installation. Figure 26.3.C.19 Front left shroud Figure 26.3.C.20 Front upper shroud (view forward) 3568-001 Right deck 3568-007 Bracket 4851-027 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.28 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Baffling Seal The flexible baffling seal roll is a soft, silicone based material that is included with the baffling kit. Steps... 1. Using the baffling seal template cut the 34 baffling seal pieces from the roll (3568-A). Note: If the baffling seal template was not included with your kit, you need to obtain the template prior to cutting these pieces. 2. Install the baffling seal pieces from the inboard side of the aluminum baffle panels. The baffling seal pieces must lay inward against the cowling top to form a good seal that tightens when pressurized with ram air. If a flexible baffle were to get blown back, a massive air leak would result and the engine could easily overheat. 3. Pop rivet each piece in place using the wide-head pop rivets (BSL42) and any washer that fits. Place a pop rivet approximately every 1-1/2” to the entire perimeter of the pressure cowl area. You'll find that once you've installed all the flexible seals, the top cowl will seem particularly difficult to get installed into proper position. As the engine heat works on these seals, the fit will improve. After a few hours of running time the cowl will not be a problem to install. Review this photo for an example of the baffling seal installation. Figure 26.3.C.21 Baffling seal kit top, flat view and positioned around the baffling pieces Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.29 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing Flanges and Grommets on the Right Rear Panel This section locates the flanges and hose openings right rear vertical panel. • Fuel pump flange, (561-1) • Gascolator flange, (561-1) • Vacuum pump shroud (optional) (1058) Steps... 1. Drill three holes in each flange. These are the holes used to rivet the flange to the rear right vertical panel. 2. Hold each flange against a hole in the rear right vertical panel. Mark each hole location on the panel. 3. Drill the holes you marked in the previous step in the rear right vertical panel. 4. Secure each flange with three pop rivets (MSC-32) and washers. Optional step: 5. If you are installing the optional vacuum pump, you will need an additional hole in the rear right vertical panel. Locate the opening as shown in Figure 26.3.C.22. Review this photo for the rear right vertical panel’s flanges and rubber seals. 145-0003 5416K15 05-29904 FM-567-058 FM-567-057 Figure 26.3.C.22 Flange locations on the right rear panel 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.30 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Fuel Pump Shroud Steps... 1. Install the 8-32 stud (518-3) on the fuel pump. 2. Install the fuel pump shroud (518-02) using the locknut and washer. 3. Now attach the SCAT-4 tubing using the clamp. This line is a 1” diameter SCAT tube which originates at the rear right vertical panel (FM-567-057) and extends back to the fuel pump shroud. See Figure 26.3.C.22 for the flange location on the right rear panel. 4. Assemble the flange to the SCAT tubing on the end away from the fuel pump shroud. Review this photo for an example of the fuel pump shroud and SCAT tubing installation. 145-0004 5418K15 MS21042-08 MS35333-38 Figure 26.3.C.23 Fuel pump shroud 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.31 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3.D Completing the Engine’s Primary Control Systems The following views of the Continental IO-550N engine acquaints you with the locations of the significant control systems. Several items are standard such as the throttle, prop and mixture. Other items may vary based on your chosen equipment, for example the type of fuel pressure gauge, manifold pressure gauge, and the oil temperature and pressure. View of the Engine Control Systems The top view is displayed at the right in Figure 26.3.D.1. The following engine control systems are installed in this section: • throttle cable • mixture control cable • prop governor cable • manifold pressure • idle mixture • optional vacuum pump mount Continental IO-550N front view. Continental IO-550N rear view. Figure 26.3.D.1 Continental IO-550N top view Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.32 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Throttle Cable and Bracket Steps... 1. Route the throttle cable through the firewall. Tip: See the firewall blueprint A3586, pages 1 and 2, for the location. 2. Next route the throttle cable through the rear left vertical panel (FM-567-058) between the oil cooler and the engine case. Review this photo for the location of the throttle cable through the left rear baffle. 3. Assemble the throttle arm. Tip: The throttle cable needs to be aligned with the throttle arm. Verify the installation location of the throttle bracket (TB563) on the engine. 4. Torque the throttle arm to 120 in-lbs. 5. Attach the throttle bracket on the engine. The engine spacers must be positioned between the brackets as shown in Figure 26.3.D.2. 6. Attach a control cables clamp (31509) on the inside of the throttle bracket. 7. Thread the cable through the clamp and adjust as necessary. 8. Connect the throttle cable with the tapered edge toward the indexing groves. Tip: When the throttle cable is tightened down, it creates its own indexing groves. Make sure it is in the correct location prior to tightening. Review this photo for a throttle arm detail view. Review this photo for a throttle bracket detail view. Figure 26.3.D.2 Throttle cable and bracket A800-BL-5 HFC-3 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.33 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Mixture Control Cable and Bracket Steps... 1. Mount the nut 91811A031 103-0026 to the stud on the oil filter base casting. Torque to 9 ft. lbs. Tip: Use Loctite 242 (blue) to install the nut. 2. The inboard end of the 565-02 bracket will fit to the contour of the engine casting. This keeps the bracket firmly in place. 3. Assemble the mixture control cable (A750-RD-5) and clamp it to the bracket temporarily. 4. Work the mixture cable from lean to rich and adjust it as necessary to get the proper travel. 5. Now adjust the bearing rod end and tighten the check nut as necessary. Tip: It is very important that the mixture control cable bracket stays put. You don’t want it to come loose at any time for any reason. Review this photo for a side view of the mixture control bracket mounted to the stud. Review this photo of an installed mixture control bracket. SP565 31-509 106-0016 91150A114 HFC-3AU Figure 26.3.D.3 Mixture control cable and bracket 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.34 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Prop Governor Cable This cable goes under the baffling. Steps... 1. Remove the two front left lower engine foot bolts. 2. Install the prop cable bracket (PG564) all the way aft, mounted on the two bolts. 3. Torque the foot bolts to 20 ft.-lbs. 4. Assemble the prop governor cable and clamp it to the prop cable bracket using the cable clamp (31509). Tip: It is typical to shorten the cable by 1/4” by adjusting from stop-to-stop using a threaded cable or an adjustable bracket with slotted holes. Review this photo of the prop governor cable installation. HFC-3 D20309-39 A750-BU-5 HFC-3 Figure 26.3.D.4 Prop governor cable 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.35 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3.E Connecting the Manifold Pressure The manifold pressure is picked up on the left side of the engine, just aft of the throttle arm. The final installation of the manifold pressure depends on which type of gauge you select. Steps... 1. Install a C5405x4x4 to the manifold pressure pickup. This is a 45° flair fitting. 2. Attach a 1/4" (6 mm) flex line to the fitting installed in the previous step. From this point the line can be routed one of two ways: • It is routed aft to an electronic sender, – or – • It is routed through the aft baffling to a sender behind the pressure cowl area or through the firewall to the gauge. If the second approach is selected, a firewall bulkhead fitting (AN832-4D) needs to be used. Generally Fireshield is not used on this line. Typically the line is then routed through the rear left vertical panel baffle piece using a MS35489-13 grommet. If you are using the VMS 1000 system, secure it using the AN3-4A bolts, AN936-A10, and the AN960-10 washers provided in the hose kit. Make sure the hose is well secured to protect it from chaffing or rubbing. Review this photo of the manifold pressure pickup. MS27404-4D 193-4 Figure 26.3.E.1 Connecting the manifold pressure Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.36 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 26.3.F Completing the Fuel System The fuel system has already been installed up to and through the firewall with the bulkhead fitting. A gascolator is attached forward of this fitting as a last catch for large particulates and water. This section covers the installation of the fuel supply and return lines as well as drain lines. Using Fireshield All fuel supply lines must be wrapped in fireshield. This not only protects against fire, but it also helps insulate and keep the fuel temperatures lower. The fireshield must be sealed at each end using a hose clamp or safety wire. Installing the Gascolator This Lancair gascolator (GAS-500F-BYP) is a high pressure type compatible with the fuel system. The gascolator has a built-in filter and all the fittings are included with the kit. The blast tube is in the hose kit. Tip: Refer to the blueprint A-504 supplied with the gascolator for specific part numbers. Steps... 1. Cut a 2” (50 mm) dia. hole in the firewall’s aft laminate and core at the location shown in Figure 26.2.0.1 on page 26.7. 2. Sand and clean the circular cutout area and the surrounding laminate in preparation for BID. 3. Form a radius around the exposed core of the circular cutout with a thick epoxy/micro mixture. 4. Reinforce the area with a 4-BID, overlapping onto the original aft laminate 1” (25 mm) around the cutout perimeter. 5. Drill a 7/8” (21 mm) hole through the firewall, centered on the coreless area you just made. 6. Install the gascolator bracket, 4876, to the firewall. Figure 26.3.F.1 Lancair gascolator parts Gascolator shroud 4875 Gascolator bracket 4876 Fitting, C5205x8 Gascolator, GAS-500F-BYP See warning on next page. 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.37 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 7. Install the gascolator assembly to the bracket using the C5205x8 fitting. WARNING: When a 90 or 45 degree fitting is used, ping or use loctite on the fittings after they are in the correct orientation. This will prevent the gascolator from working lose and potentially sucking air. 8. Attach the gascolator shroud, 4875. 9. Thread a bulkhead 2240-6-8S fitting into the gascolator from the aft side of the firewall, through the hole you drilled. This sandwiches the firewall between the gascolator and the fitting. 10. Thread an AN816-6D fitting into the 3200x8x6 adapter fitting. Now you are ready to connect the gascolator to the electric fuel pump that you installed in Chapter 14 Fuel System in 14.3.C Installing the Electric Fuel Pump on page 14.8. Connecting the Gascolator The following connections need to be made: • In connection – from the fuel pump to the gascolator • Out connection – from the gascolator to the fuel pump • Top connection – from the gascolator to the baffling port Steps... 1. Connect the flexible hose coming from the fuel pump to the gascolator by connecting it to the gascolator fitting on the aft side of the firewall. 2. Attach a straight or 90° fitting to exit the gascolator. While we've had no problems with an aluminum AN822- 6D fitting, it is common practice to use steel fittings which connect between stationary and moving engine parts. In this situation an AN822-6 fitting is used. 3. Install SCAT tubing at each end. Use the tubing included in the hose kit. 4. Install the inlet flange. Tip: Refer to the blueprint A-504 supplied with the gascolator. Figure 26.3.F.2 Gascolator installed on the forward side of the firewall Fitting, C5205x8 is underneath the fireshield Gascolator Gascolator shroud 4875 Firewall C5205x8 fitting Hose & Tube clamp 145-0003 (11/16” - 1 1/4”) 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.38 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES Installing the Fuel Lines Remember, after all the fuel supply lines are installed they must be wrapped in fireshield. Steps... 1. Verify that all the appropriate baffling flanges have been installed as described in Figure 26.3.C.22. 2. Install the following grommets in the rear baffling. Grommet MS35489-13 – for the manifold pressure, see Figure 26.3.E.1. Grommet MS35489-21 – for the fuel pressure line. 3. Secure the fuel supply line, 1/2” (12 mm) hose 517, to the engine intake. WARNING: All fuel supply lines are now 1/2” (12 mm) hose. In older versions of the kits and the manuals they were 3/8” (9 mm) hose. 4. On the other end of the same fuel supply line install a fuel flow transducer using fittings C5205X4X4. The fuel flow transducer requires two of these fittings, one on each side of the transducer. The fuel flow transducer must be installed following the manufacturer’s recommendations. 5. Install another fuel supply line (537) from the transducer to the fuel pump. 6. Install the last piece of fuel supply line from the fuel pump to the gascolator. If you have a gascolator without a filter, the fuel filter should be installed between the gascolator and the fuel pump. 7. Wrap the transducer with fireshield. Note: The fuel flow transducer will vary depending on the avionics. MS21919-DG32 MS21919-DG10 MS21919-DG12 193-4 532 AN822-4 AN910-1 Figure 26.3.F.3 Fuel line layout 2/04-30-2008 Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756 Chapter 26 Page 26.39 REV 0/04-04-2005 Firewall Forward – Continental IO-550N ES 8. Secure a fuel pressure line, 510, to the engine intake fitting. Thread the other end of the line through the baffling grommet MS35489-21. Note: For metered fuel pressure use a 9-420026 fitting. 9. Connect a fuel return line, 1/4” hose 532, to the fuel pump. This line will connect to the fuel return bulkhead fitting on the firewall that was installed in Chapter 14 Fuel System. 10. Install the following drain lines using 1/4” hose 193-4 and run the lines overboard. • fuel distributor • fuel pump drain lines overboard. Use 193-4 hose. Figure 26.3.F.4 Fuel supply and fuel pressure lines Fuel transducer wrapped in fireshield. Fuel pressure line, hose 510 Engine intake. Attach fuel supply and fuel return lines. Fuel supply line, 1/2” hose 517 2/04-30-2008