INSTALLATION INSTRUCTIONS
STEP 1:
Measure down from the lower horizontal nose gear upper support holes by 113mm, and outboard to the left of the aircraft from the left hand side of the Center Steering Structure (75F9-4) holes by 103mm. This will set the placement for the holes in your oil tank mounting bracket. Mark these holes, but do not drill yet.
Mark all lines as shown in the layout below. These lines will be used later.
Mark all lines as shown in the layout below. These lines will be used later.
STEP 2:
At this point you'll need to cleco on the Zenith supplied diagonal firewall stiffener on the aft side of the firewall (from the bottom steering area towards the upper engine mount bolt hole area).
As shown in the images below, mark the centre line of the z-stiffeners and then place them on the lines that you laid out in Step 1.
Be sure to trace the stiffeners to ensure proper hole edge distance specially to the top and bottom holes marked for the oil tank mounting bracket. You may need to adjust the height of the z-stiffeners.
As shown in the images below, mark the centre line of the z-stiffeners and then place them on the lines that you laid out in Step 1.
Be sure to trace the stiffeners to ensure proper hole edge distance specially to the top and bottom holes marked for the oil tank mounting bracket. You may need to adjust the height of the z-stiffeners.
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At this point you may drill all marked holes through your firewall (where the z-stiffeners go and the oil tank mounting bracket). Tape the Z-stiffeners on and then mark the holes through the firewall. Remove the z-stiffeners and then drill through them.
Reinstall the z-stiffeners along with the oil tank bracket with clecos and with even spacing, drill 6 more holes in the BOTTOM z-stiffener (1 between the diagonal angle and the oil tank mounting bracket, two between the oil tank mounting bracket and the steering nose gear support structure, two inside of the steering support structure, and 1 to the right of the steering support structure).
On the TOP z-bracket, with even spacing, drill 9 more holes through the firewall (two between the oil tank mounting bracket and the vertical nose wheel support structure, one inside the nose wheel support structure, and 6 between the oil tank mounting bracket and the diagonal L-bracket.
Deburr all holes
Reinstall the z-stiffeners along with the oil tank bracket with clecos and with even spacing, drill 6 more holes in the BOTTOM z-stiffener (1 between the diagonal angle and the oil tank mounting bracket, two between the oil tank mounting bracket and the steering nose gear support structure, two inside of the steering support structure, and 1 to the right of the steering support structure).
On the TOP z-bracket, with even spacing, drill 9 more holes through the firewall (two between the oil tank mounting bracket and the vertical nose wheel support structure, one inside the nose wheel support structure, and 6 between the oil tank mounting bracket and the diagonal L-bracket.
Deburr all holes
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At this point fit the fuel shut-off bracket and water coolant expansion bottle brackets to ensure rivet alignment with the z-stiffeners.
Once those kits are fit and in proper alignment, all brackets may be riveted onto the firewall.
Once those kits are fit and in proper alignment, all brackets may be riveted onto the firewall.
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