Firewall Forward

I have decided to build my own firewall forward setup that is largely based on the VANs design.

The reason is simple – I can’t afford the the FWF kit from VANs.

So bought a secondhand Rotax 912ULS engine, engine mounts from VANs and source the rest of the components locally.

I have purchased the engine from a flight training school with nearly 2000 hours on it. Compression check showed good numbers and it looks like the engine has been well maintained.

Links with pictures for the FWF

• Lots of detailed pictures for exhaust and cooling: http://torstensrv-12.blogspot.com/2012/07/exhaust-installed.html
• Detailed pictures of the new design exhaust: http://natesrv12.blogspot.com/2017/01/exhaust-system.html
• New exhaust design discussion http://www.vansairforce.com/community/showthread.php?t=126843
• Exhaust SB discussion: http://www.vansairforce.com/community/showthread.php?t=171730
• Interesting post about exhaust heat shield http://www.vansairforce.com/community/showthread.php?t=59578

 

Exhaust System

• Company in Italy selling exhaust components: https://www.enjoy-ulm.it/enjoy-ulm/shop/exhaust-system/
• Exhaust system and components: http://www.rotax912exhaust.com/en/
• Another supplier http://www.cktengineering.com/aircraft-exhaust-systems/index.html

 

Electric system

• Wiring tips: http://www.flight-mechanic.com/wiring-installation-and-routing-part-two/
• More wiring tips: https://www.aircraftsystemstech.com/2017/05/wiring-installation.html
• Power circuit with external input: http://www.flight-mechanic.com/aircraft-electrical-systems-small-single-engine-aircraft-part-one/

 

Voltage Regulator

• Default: Ducati Energia 362001 or 343620. Great article about them http://contrails.free.fr/elec_ducati_en.php
• John Deere AM101406 (~$56AUD on Amazon delivered, assumed Chinese fake)
• John Deere MIA881279
• NAPA SME 7068102 (Possibly the same as John Deere AM101406)
• SILENT-HEKTIK F4112 or F4124 197,00€ http://www.silent-hektik.de/UL_R_912.htm
• Schicke GR6 – VR for Rotax with adjustable voltage
•  CARR5115 $251 AUD https://www.vectriqparts.com.au/product/carr5115-rotax-voltage-regulator-343620-362001/
• Advanced Voltage controller $250-300 USD https://bandc.com/product/avc1-advanced-voltage-controller-homebuilt/#installation-kit
• SHINDENGEN FH020AA  – fake ones are $55 AUD on ebay. “real” ones $120 US https://roadstercycle.com/index.htm
• DIY unit http://contrails.free.fr/elec_alt_miller.php

Great articles on the subject of Voltage Regulators:

•  http://ctflier.com/topic/2371-regulator-rectifier-longish-and-techie/
•  http://www.dogaviation.com/2016/01/the-ducati-voltage-regulator-dilemma.html

 

Starter Relay

• OEM part number Denso 182800-1950 ~ $100 US
• Original Rotax part number 992 819 ~$130 US
• Preferred option is Lawn Mower starter for $20

 

Oil Pressure sensor

 

Oil Temperature sensor (same as CHT/coolant sensor)

• Rotax part number 965351
• VDO 323-801-010-001D (most likely)

Specs:

• Datasheet – possibly equivalent to Thermistor 92-027-006 https://www.vdo-gauges.com/media/instructions/TU00-0770-5104620%20Temperature%20Sensors_short_version.pdf
• Thread: M10x1.5
• Max temp – 150C
• Length: 21mm