INSTALLATION INSTRUCTIONS
To install this kit you must have your cowling and nose bowl completely fit.
Remove Lh And Rh side cowlings.
Remove lower cowling.
Using the measurements in the picture below as a guide place a masking tape line on the lower cowling upper Lh side at the measurements shown. Place two more masking tape lines left to right near the back for marking position of the angles that will be mounted to the cowling bottom. You will need to zoom in on the pictures for measurements. This is a reference only as your aircraft may be different. This is a 915 installation shown and your exhaust outlet will probably be different than shown. Your dimensions may be different depending upon prop used and cowling length.
Remove Lh And Rh side cowlings.
Remove lower cowling.
Using the measurements in the picture below as a guide place a masking tape line on the lower cowling upper Lh side at the measurements shown. Place two more masking tape lines left to right near the back for marking position of the angles that will be mounted to the cowling bottom. You will need to zoom in on the pictures for measurements. This is a reference only as your aircraft may be different. This is a 915 installation shown and your exhaust outlet will probably be different than shown. Your dimensions may be different depending upon prop used and cowling length.
Install lower cowling with a few screws to hold firmly in place.
Place air scoop inlet shown (as bare metal) above in position. Bring back edge of this piece so you have about 3/8" to 1/2" space between it and the muffler on the bottom and the back side.
Center it to the muffler.
Mark on the tape where the front edge of this lies on the cowling. This will be where you drill and cleco the forward edge for the starting point. It's easier if you remove the cowling and drill from the inside going down.
Place air scoop inlet shown (as bare metal) above in position. Bring back edge of this piece so you have about 3/8" to 1/2" space between it and the muffler on the bottom and the back side.
Center it to the muffler.
Mark on the tape where the front edge of this lies on the cowling. This will be where you drill and cleco the forward edge for the starting point. It's easier if you remove the cowling and drill from the inside going down.
Picture above is taken at an angle so its hard to see the 3/8" clearance but its the best I have right now.
Clamp the U channel with the hole to the intake piece that you just clecoed in position. This should be centered on the 2 inch outlet.
Drill and cleco from the back side.
Clamp the two cowling angles shown above to this piece.
Reinstall the bottom cowling temporarily again.
By slightly twisting the angles you can get good and parallel spacing to your muffler. Check both sides and bottom as well as the back. Mark on the tape where the angles are located when in its best position.
Remove cowling and drill the angle holes into the bottom cowling. Cleco in place.
Reinstall cowling one more time. This is your last chance to get everything aligned parallel.
Adjust clamps between angles and U channel until you are happy with clearances.
Read the balance of installation instructions before you next drill. as there will be a total of two holes on each side when finished and you need to place holes accordingly.
Drill and cleco one of two holes on each side.
Rivet all parts together except for this last hole you just drilled with A4 rivets.
The last hole will get the AN3 bolt and nut.
Reinstall cowling, verify fit, tighten bolts up and drill two more 1/8" holes. These will get an A4 rivet in them so there is a bolt and rivet on each side of the U channel at the bottom going through the angles. This prevents the U channel from pivoting on the bolts.
Drill and cleco from the back side.
Clamp the two cowling angles shown above to this piece.
Reinstall the bottom cowling temporarily again.
By slightly twisting the angles you can get good and parallel spacing to your muffler. Check both sides and bottom as well as the back. Mark on the tape where the angles are located when in its best position.
Remove cowling and drill the angle holes into the bottom cowling. Cleco in place.
Reinstall cowling one more time. This is your last chance to get everything aligned parallel.
Adjust clamps between angles and U channel until you are happy with clearances.
Read the balance of installation instructions before you next drill. as there will be a total of two holes on each side when finished and you need to place holes accordingly.
Drill and cleco one of two holes on each side.
Rivet all parts together except for this last hole you just drilled with A4 rivets.
The last hole will get the AN3 bolt and nut.
Reinstall cowling, verify fit, tighten bolts up and drill two more 1/8" holes. These will get an A4 rivet in them so there is a bolt and rivet on each side of the U channel at the bottom going through the angles. This prevents the U channel from pivoting on the bolts.
Your inboard angle will not have two rows of rivets as the one shown here has.
Find a place on the firewall with reasonable access to install the stainless cabin heat shut off firewall valve. Drill your 2 3/16" holes and one 2" hole through fire wall. Mount with silicone gasket. (I like to have it positioned by the pilots feet)
Place cabin heat control in a convenient location and run it to the shut off valve. Support and clamp as required.
Position arm on valve for full and correct movement.
Cut cable to desired length and wrap wire in a loop to go around a screw or bolt on the control arm.
Trim hose to length and install.
Place cabin heat control in a convenient location and run it to the shut off valve. Support and clamp as required.
Position arm on valve for full and correct movement.
Cut cable to desired length and wrap wire in a loop to go around a screw or bolt on the control arm.
Trim hose to length and install.