Ly Eng ycoming gine Inst g O-320 tallation into a L n
Contents
1. VALVE Co preR Axa 1 LINE TO dn 814 G SAANCH An 19 D lf Ap N 8IL 6D PUTEM An 9 9 j Lc MINI iy CT KA IST fu 832 6 GASCOLATOR FUEL PRESSURE giri Y d 3 4823 gt Senper amp amp r amp c 441 FINGER STAMERT COMES WITH CARE MARVEL SNEEK PART WATER DRAIN Au 3232 6 6 D A Ek on AEK0Qui P 491 6 AN 22 KN ELECTRIC Ork PRESSURE Der Loc v Sra An823 Gp d i Ap eeu VPO Musr wave wee OR FACE Aso oa JS Ti R 35 LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 1 Micro switch type V3 or Radio Shack 275 1102 Engine Mount Hardware For Conical Mount 4 AN6 43A Bolts 4 AN960 616 washhers 4 Lyc std 619 Washers 4 AN363 624 Nuts 8 71032 Rubber Bushings OR For Dynafocal Mount 4 AN7 35 A Bolts 8 AN960 7616 Washers 4 AN363 720 Nuts 8 Dynafocal Bushings for 2 3 4 D Retainer 4 Steel Spacers Baffle Material 5 of 1 8 x 1 x 1 1 2 2024 T3 Alum Angle 1 pc 025 606116 Alum Sheet 30 x 48 1 pc 1 16 x 12 x 40 Neoprene Asbestos 200 Avex 1601 0410 Pop rivets 200 AN960 4L Flat Washes 12 AN500 A416 10 Baffle Screws 12 AN936 A416 Lock Washers 2 AN931 6 16 Rubber Grommets 48 of 2 1 2 dia Scat aeroduct 12 of 2 dia Scat optional cabin heat 12 of 1 1 2 dia Cat optional cabin heat 4 Stainless worm clamps 1362. EI aH PI UN Ke Tui 35 L j Eg Fa T di 1 d VA pu Pi EN aid L PF x eg SCH L I 8 ae 5 Bar periti T cem s la gt Mia ie AA n Servino CARE Controls RACKET E _ Fal SALE 8 iue DARA il lam 53 27 25 Z3 9N9 YUH IOI YI 7 TY ER Ni 318 Ss Ce SY wa ANY crono ava sg PALA mow pu 72 5 7 mele adi smo I op sub AT 8 E A et blany 3017 aed 25 e awed 527 2 YAN Lei H T AvaH yy 2 1 D w 28 54 335 ET a NW A UN SCH 8 Pe ab SIHL MIYA 5 275 bia NY TW dv dny 18 p aah va dLy2as YHND 1 NOILNYD Gy ora a I c Sowia 4 25 2 40 Sp 3noqe 3je ul 3ut Aayj umoys se umop 346194315 10100 jou op dund ay3 uo sfui33 j pZ 9 228NV 241 930N SN JOF 67 Long 2 SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 over the cut end of the cable it will save sane pain and expletives later The throttle
3. 41304 ENGINE Mounr Exrfusion r CANTS INBOARD 2 2 r yp w l 12 96 W L 12 96 I I 1 1 I I I I I I 1 ES ai 128 129 3 3 132 432 13 135 136 q 6 5 4 2 3 1 0 3 D E 7 e 4 Long EB SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 Install the BA brake arms onto the upper engine mount extrusions as shown NOTE the BA brake arm has reversed from the original drawings show in section because testing has shown considerably better brake effectiveness this way You will need to slightly alter your Brock BA brake arms to conform to the full size pattern below Also the hole in one end of BA as received from Brock should be drilled out to 5 16 dia Her 0 DIA j d SG Die Mes BA BRAKE ARM PATTERN Now install you BA brake arms on the inboard side of the upper engine mount extrusions The pivot bolts will obviously be too long at this point since the engine mount is not in place Temporarily use a spacer or washers in order to rig the brake arm master cylinder and brake actuating cables Refer to Section page 16 8 Now remove t he pivot bolts AN4 14A and brake arms and push the mount into position on the aluminum extrusions Space the ends of the mount tubes aft of the firewall approximately O 030 and clamp the mount firmly into position on the aluminum extrusions Use the existing holes in the upper extrusions as drill guides t
4. ane ion TUBE LA RADIUS APPROX SAND ALUM Ke TUBE Tp Secrion 7 IRC Ai BID To Akur 1 Carve a urethane foam block in the correct shape with the sanded 2 5 tube stuck over one end 2 Mount the block on a flat surface covered with duct tape release 3 Layup the 4 plies BID overall over lapping small pieces is ok 4 After cure dig out the foam and drill Long EF STEP VII AIR INDUCTION SYSTEM This page shows details on how to make the carburetor inlet elbow This elbow will bolt to the inlet flange on the bottom of the carb A gasket should be used or sealant that is fuel proof not RTV silicone When you build the fiberglass elbow be sure it is oriented correctly to point forward at the carb air heat valve Next mount a length of CAT 10 or SCAT 10 to the elbow Pay careful attention to the clamping details shown Do not substitute ceet or sceet hose Route the inlet hose to the bottom of the carb air heat valve and clamp it in place The inlet how should not be stretched tight A little slack is required to allow for engine shake during operation Drill a 74 dia Hole in the low point nose gear retracted with no electric starter and 3 point with a starter of the air inlet how to allow excess fuel to drain for a flooded start A F 25 i To make this 1 4 holes d ei ar FATT e bel mum Spal x fer raima m D e kas
5. AuFF jT SHewn for CLARITY SEE 33 Note THE KES Bock BALL Jost 19 gt 4S A UNIT AND Toes Nor feaurRE HARD WARE o4 SPRINGS AVAILABLE FKom hr ULI eer 4 leq og 54 IT s BRook IF you pecio ro KE Bock MFG Home BUILD THE EXHAUST BALL Towt rvf View Look ic INBOARD 4 Raut RIGHT Sus LOOKING ap ILL 31 LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 NOTE BATTLES THIS PHOTO ARE oBSoLETE Top View LEFT ExHAUST HALE SCALE AU 5 2 ESS STEEL l Z STAIN 1 2 Lows AS DIA 06 wire LEFT SIPE LOOKING Apres Vo Dia x 035 WALL SON Sree TUBE HEAT ad FLATTEN Eops FAGRICATE TO FIT Typ proRi Eor on ro A KeckeX corek SCRE A see Photo P3 34 View LOOKING INBOARD FRom LEFT SECTION Il Long EF 5 BM SN JOF 67 Irap x 035 606 T6 Al Tuk HELI AKc WELD eK PAIL Smaak HeLes ALL AKous TD Born TUBES HAD SEW THEM TOCETHER wiTh SAFETY WIRE for GENEROUSLY WITH cinicone CARB AIR HEAT VALVE 4 8 E DPA SCAT HESE Apfkox ib oral a 8 SCAT nose SEE premi A Brock EXHAUST ap FWP we ls ol lt SPAR WD im _ COLD Ram AIR If you decide to home build this heat exchanger it is very important that no carbon monoxide can get into the coc
6. Flight Path Indicator ENGINE MONITORING Flexible Gauge Layout layout editor Flexible Pin Assignments Tachometer Manifold Pressure Tachometer EGTs CHTs GP thermocouple 14 Fully Configurable Thermocouples Oil Temp Oil Pressure Coolant Temp Coolant Pressure Fuel Pressure Ammeter Voltmeter Fuel Flow Fuel Level Trim Position Flap Position SECTION II LYCOMING O 320 ENGINE INSTALLATION Long EF Option Il Digital System SkyView SV D1000 SkyView Displays utilize TFT active matrix LCD screens and LED backlighting technology for increased life span more uniform brightness and reduced power consumption Buttons and Joysticks The SkyView System is designed for ease of use while flying The most used functions are accessed via two rotary multi direction Joysticks for fast intuitive commands Almost all other in flight commands using the widely spaced buttons are only two button presses away None or more than three button presses Redundancy If two displays are in the system either one can act as the Primary Flight Display Moving Map and Engine Monitor The unlikely loss of either display will not affect the functionality of the other System Battery Backup A system backup battery will provide over an hour of backup power to a Display and Modules Each Display requires its own Backup Battery for redundancy Connections Each display contains 1 37 Pin DIN Connector for the main wiring harnes
7. as possible The controls must work without the return springs Check this before installing the springs The springs take all of the slop out of the system for smooth throttle and mixture control but do not depend on the springs The springs will return the throttle to full open and mixture to full rich In the event of a cable failure ciel 10 stone GEND MOST PLASTIC 08 dou sING Mark the cable housing to be trimmed so that it protrudes about 7 beyond the housing t clamp Before you try cutting the cable housing to final length try a practice cut way out on the end of the housing The idea is to use your dremel stone grinding wheel to grind part way through the housing wire not into the cable see sketch and then break the wire with a twist using pliers Don t damage the cable inside With the housing cut to length you can use your dikes to cut the cable Be sure you have enough extra cable to make a loop around the AN111 4 thimble Install the mixture arm bracket on the carburetor mixture as shown Bolt CLAMPS oN A 1 4 OD x 3 STL SPACER THE AN Ili ai CAEL GEANE NOS d FOTATE FREELY RB CONI KET Pg 16 AN 3 76 AN 990 3 M 71042 3 STOP Lob 7 1 16 Welt t btw ATEH l WITH D l SATT Y uxilek Tuer Alem VIEW From LECT Va x Big x 25L SPACER 8 I C NicoPRics Hig SECT A A Clamp the cable between yo
8. cable is installed in a fashion similar to t he mixture A Centry Spring Corp C 161 spring is used to preload the throttle in the full open position see photo TRROTILE ARM JARDWARE VIEW Loo G LEFT y ox hoo ALn a 493 1 uel HOTO CI6I SPRUE The throttle cable is swaged with an AN111 4 cable bushing and 18 1 C sleeve as s own The cable is attached to the throttle arm with an AN3 7A bolt 3 16 ID x 4 OD X 25 long spacer AN970 3 washer and MS21042 3 nut as shown in the sketch The AN111 4 must rotate freely on tile spacer Double check the throttle travel in the cockpit and at the carburetor before swaging Dab the cut cable end with silicone rubber The carburetor heat cable housing damp cable and return spring are installed as shown on page 8 Don t force the cable and housing around tight corners leave enough slack for a gently loop to the cable housing clamp Next attach each magneto ground to the electrical wires running forward to the mag switches A schematic diagram is shown for the installation of mag wiring below Connect the switches to the aircraft ground as shown Connect the aircraft ground wire to one of the engine mount bolts Install a short length of braded strap from the mount to a convenient stud on the engine Install your CHT probe on the number 4 cylinder top side During your initial runs and initial flights you should move the probe to other cylinders Once the hot
9. em a 0 S u 3 x a 5 E P z xr iL a v gt 4 l ea i J O T 2 ZER 1 50 a d zc Long EB SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 yoo TEMp RTE Rie wy Sor a 254 DIT SEE nore on ee 4 cowl 16 close E 3 8 HERE RIGHT REAR 2 KIGHT 436 o EEo up Jo Aw iS O W Hove A I SN JOF 67 80 pio up P SMALL HOLES FOR SAFETY LIRE INTER CYLINDER BAFFLES a gt MATL GOGI TE Accum ORS SECTION II LYCOMING O 320 ENGINE INSTALLATION RIVET A DIAGONAL BRACE NERE SEE Pq 26 25 photo O25 Long EB 6 FoRwARD CENTER BAFFLE LOOK IG FekWARP mart 6 5 Atum Rone pek Puoro PHoro SMALL WeLE For SAFEFY WIRE TREND up Ss INTER CYLINDER HEAP BAFFLE 2 gt Mare LOGI TG Zum 3 PER ba 54 JI ENGINE INSTALLATION SN JOF 67 FoRWARDP_RIGHT BAFFLE LOOKING FoQwAQD_ MATERIAL GO6IT G ALUM ORS p DIA HOLE IGNITION HARNESS SEE Pa 25 2 MOUNTING Hore LYCOMING O 320 Long EB SECTION II Ye pop Rivers 2 pecs FokRwARD BAFFLE CENTER GRAC
10. j Y _ Apply a strip of grey duct tape to the inside surface of the outboard edges of the top cowl This will allow you to release the cowl edges from the glass attach flanges in the wing roots Remove the exhaust system if installed and with the spinner in place jig the cowling into position such that the spinner roughly centered in the trailing edge opening If you intend using starter the ring gear should be positioned so that you have no less than O 4 clearance between the top cowl and the teeth on the starter ring gear The cowling trailing edges should match pretty close to the wing root trailing edges The cowl leading edge lips should rest on your wood blocks Drill 30 dia holes through the leading edge lip of the top cowl into the wood blocks Space and position these holes so that they can later be enlarged and used for the 10 32 screws to attach the cowling Remove the bottom cowl lift the top cowl and put a small blob of Bondo on each wood block and cleco the top cowl into position When the Bondo hardens remove the clecos and apply a strip of grey duct tape to the leading edge lip of the cowling This will allow you to release the cowl after you have layed up the cowl attach flange Position the outboard edges of the top cowl so that they accurately follow the contour of the wing roots Locate the top cowl edges in this position by glueing popsicle sticks across the wing root cowl joint with small dabs of Bondo S
11. layup a closet rib in the trailing edge of the cowling layup fiberglass attaching flange along the centersection spar fuselage and wing roots and attach the ram air inlet to the lower cowl You will also fabricate a sheet metal oil check door and install the upper baffle ribs The cowling is attached to the airplane with 410 32 screws AN507 1032R10 nut plates K1000 3 and countersunk washers A3235 028 24A Camloc fasteners may be substituted as a quick disconnect feature along the wing roots top bottom and along the cowling trailing edges Camlocs along the centersection spar and fuselage are not recommended due to the requirement to physically remove the camloc before the cowling can be pulled out from under the attach lip Dzuz type fasteners should not be used as t hey do not provide adequate shear load carrying capability The vendor supplied cowling halves are intentionally supplied a little too wide Hold your cowling in position against the firewall aft edge of the center section spar and mark along the wing roots It is much easier to install the cowling with both wings mounted on the aircraft and with the engine mounted and spinner at least located on the prop flange Trim the cowl span wise to fit Now sand the inside trailing edge of the top cowl half and apply shiny surface grey duct SN JOF 67 Now lay up 5 ply BID flanges across the center section fuselage as well as under the top cowl out board ends into the wing
12. to pass aft of the aileron pushrod Note the EFP fuel pump is drilled and tapped with a 1 8 pipe thread as is the Bendix fuel pump and you will require two special elbows AN822 6 2D which are available from a Long EZ distributor Plumb from the electric boost pump to the mechanical pump on the engine using aeroquip flexible hose 303 hose 491 hose fittings are called out but you can substitute aeroquip 601 hose and 1816 fittings At this time you can mount the optional cabin heat valve available from Ken Brock Mfg or you can easily build one yourself from the information on page 9 Be very careful not to drill in to the lower centersection spar cap when mounting this valve A good method of mounting the valve is to glue it to the firewall with RTV silicone STEP VI MOUNTING THE ENGINE With the exception of the hardware mounting the conical or dynafocal engine is essentially the same You will require an engine hoist or a block and tackle from a rafter or several strong friends Load the front cockpit with ballast so that the airplane does not tip over when you mount the engine Hoist the engine into position on the mount and hold it there All four shock mounts bolts and nuts are now installed Be careful not to bash the engine or accessories against the mount particularly the mechanical fuel pump As you fit the engine up to the mount support the engine weight until all four bolts and nuts are torqued up Torque requir
13. to the 8 long pieces of extruded angle and the locate the 1 6 long pieces of extruded angle in the correct position and bolt them into place You will now have 4 AN509 10R8 screws bolted into each top engine mount extrusion which when viewed from aft will look like an upside down T A 1009 countersink is required Now you are ready to install the extrusions into the fuselage You should do this dry the first time that is using dry BID cloth where 10 plies are called for Install all 4 extrusions and clamp your engine mount into place with C clamps Check the fit of the extrusions and REFELZEACE ENGINE MOUAT TUBE Top LEFT ENGINE 67 Le Louk Tof LEFT ENGINE MOUNT VIEU FRom LEFT LOOKING MBoALDP gt EXTRUSION VIE FRom AFT a l 6 2x 2024T3 REF ENGINE Mouar TEBE Loe LEFT ENGINE Mounr View FReey mr Now remove the engine mount and refer to Section page 15 2 Step 3 Note that the full size view AA is not representative and you should use the full size drawing on page 7 of this section Make one left and one right hand CS73 bracket and install them on the lower engine mount extrusions using one AN509 10R 8 screw and one MS21042 3 nut per bracket as show lt LOWER LEFT ENGINE MOUNT VIE Rom LEFT LOOK NG N BOARD Now while the fuselage is upside down drill the holes through the extruded angle and center section spar and short longeron It is very handy he
14. vil ae save much grief later on should you decide to install a fuel flow indicator or whatever Pot the wiring bundle generously with RTV in the firewall Remember the wiring bundle will vibrate with the engine and care should be taken to prevent any possibility of the wires being chafed where they come through the firewall If you have a full electrical system including starter and alternator you will have a large bundle of wires It is of course permissible to split the bundle up into two or more and run half of them down the right side In this case be sure that there is no possibility of interference with the control system and bond the wiring bundle to the right fuselage side preferably in the bottom corner with the fuel lines using RTV All wiring should go through the firewall on the left side so any wiring going down the right side must be routed across the aft face of the rear seat bulkhead in such a way as to not interfere with rudder cables and aileron torque tubes Be sure and label each wire then coil the excess length of the bundle and tape it to the firewall so that it won t get damaged If you solder any wires magneto switches be sure and use good quality solder intended for electronics work SECTION II LYCOMING O 320 ENGINE INSTALLATION Long 5 STEP Il INSTRUMENTATION AND WIRING In this step you will mount your engine instruments switches and route all of the associated equipment to the firewal
15. 2 1 2 dia 2 each CS springs 1 2 long x 35 0 D x 06 wire compression 2 each Century C 161 Springs Optional 1 Essex Primer K2404 1 8 1 Harrison Oil Cooler P N 8526250 Long 5 SECTION Il BILL OF MATERIALS 6 AN3 7A Bolts 2 AN3 14A Bolts 2 AN4 12A Bolts 4 AN4 13A Bolts 2 AN4 14A Bolts 18 MS21042 3 Nuts 8 MS21042 3 Nuts 10 AN509 10R8 Screws 2 AN111 4 Cable bushings 3 AN818 2D Nuts 3 AN819 2D Sleeves 6 AN818 6D Nuts 6 AN819 6D Sleeves 2 AN822 2D Elbows 4 AN822 6D Elbows 2 AN822 6 2D Elbows 2 AN822 6 6D Elbows 1 AN816 2D Nipple 1 AN816 4D Nipple 2 ANB16 60 Nipples 4 AN823 6D Elbows 1 AN910 1D Coupling 1 AN912 1D Bushing 1 3600 x 4 Weather Head Male Branch Tee 2AC 6470069 Adapters 2 Aeroquip491 4 Fittings 4 Aeroquip 491 6 Fittings 8 33 Aeroquip 303 6 Hose 84 6 Aeroquip 303 4 Hose 4 Blow proof exhaust gaskets Lyc 77611 8 Lock Washers MS 35333 41 8 Exhaust Manifold Nuts Std 1410 5116 18 Lyc 18 3 8 0 D x 035 wall 4130N steel tube 18 3 4 1 D x 1 8 wall tygon plastic tube 6 3 4 0 D x 049 wall 6061 T6 alum tube 8 3 16 x 3 4 202413 alum bar 24 Nylon ty raps 6 long TY 525M 24 Nylon ty raps 12 long TY 528M 1 tube high temp RTV silicone red or silver Only required if an oil cooler is used Only required if a primer is used Electrical Brock Supplied Components Carb heat mixture throt
16. E MATL amp 06l T amp ALum 032 y BEND up 4o HOLE L 25 8 lt SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 Arr RIGHT BAFFLE LOOKING FORWARD MATRIAL LAGI TE ORS Kou p SEc Mite Hero o MU ss sas SEE will 6 Ore SAFETY WIRE TO uev Bn Q 8 ni To e D Pres H Cy L Cy A Sy Be H vx 70 FNM T D G Wa Y y J x Toa d SN JOF 67 ENGINE INSTALLATION T CENTER BAFFLE LOOKING FORWARD MATERIAL Drill Two 3 HelES In Battle d SHORT LENGTH 7 F 303 4 Hoze SECT A A BAFFLE SUPPORT Aqloo TY STRAP LYCOMING O 320 BASF le Long EB SECTION Il 82 SN JOF 67 Rou per AFT LEFT BAFFLE LOOKING FoR WARD MATERIAL 5 AN S a lt e P ef A qD fot 6 i SS arr d d of p g D 6 0 PT LYCOMING O 320 ENGINE INSTALLATION Row per Proto SECTION Il Long EB OZ 54 OG D 7 EF SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 ai y ar Top Wei Kent gr FEN 7 BIX LHM Exuaucr HALF Sca Au tures 1 op FREIRE Ao STAINLESS NOTE HEAT
17. Long EB SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 Engine Installation Lycoming O 320 into a Long EZ Long EB SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 INTRODUCTION Section IIL provides engineering information and documentation for the installation of any one of various models of the Lycoming O 320 aircraft engine into a Long EZ THE ENGINE As you become more knowledgeable about the Lycoming 0 320 engine you ll soon discover that there are some model variations The commonality of all models and dash numbers etc that makes it possible to cover their installation in one manual is this all O 320 s are dimensionally similar the cooling characteristics are similar the cowling fits them all The Lycoming O 320 series engines are four cylinder direct drive horizontally opposed air cooled models The cylinders are of conventional air cooled construction with heads made from an aluminum alloy casting and a fully machined combustion chamber The cylinder barrels are machined from chrome nickel molybdenum steel forgings with deep integral cooling fins ground and honed to a final specified finish The O 320 series engines are equipped with a float type carburetor Particularly good distribution of the fuel air mixture to each cylinder is obtained through the center zone induction system which is integral with the oil sump and is submerged in oil ensuring a more uniform vaporization of fuel and aiding
18. N JOF 67 STEP X OIL CHECK DOOR You will need to fabricate a door from 032 thick 2024 T3 aluminum sheet to fit into the recess provided in the distributor supplied cowling This door is attached to the cowl along its lower edge with 3 long aluminum hinge One half of the hinge should be reversed to make up the difference in thickness of the cowl and door as shown Note that the supplied cowling is reinforced around the area for the oil check door You will cut out the center of the recessed area leaving a lip all around with the exception of the lower edge where the lip must be removed locally to clear the hinge a Dzus type fastener should be used to hold the door closed B B 0382 AWM Toce CEN apuq SIDE ONE HACE OF ME 15 EAR TO MAKE of Deor must Fit TM DIFFERE UE IN SNUG AIF will oF T Cow AND Lech Leak Tore Foe Ar enk SETON E ie boPPLILO Dis TRIBUTOR fe cor THE CENTER OUT Aus A Ar uP AL T ec 2024T 3 ice CEXUETEC Aut lt Toutes Fax TO Gon PE SECTION A A amats WNG THE ALP most EE TS CLEAR TE HINGE Tb Cow C mLoc Kecepracae SECTION II LYCOMING O 320 ENGINE INSTALLATION Long EF Some builders may have a VariEze cowling or a real early production Long EZ cowling If you do it can be used on
19. SED FOL BARLE SEALS Long EB SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 CARR MEAT VALVE PARTS 2024 73 TUBE FULL SILE Do nol MmodIiFfY THIS HOLE SIZE OR CZAR LE will SLIP 2S 1 ALUMINUM FULL SIZE CABE House CLAMP ASSEMBLY RADIVE TD EC VALUE SHAFT 3 REQ D 75 MAKE 3 ASSEMBLIES USE ONE Fel THE HEAT VAL THE OTHE TID ARE For wo MIKTULE ONAL CABIN WERT VALVE Slant TLATE WITH 4 l 4266 7 3 Rwers aii ANS3I 5 5 prommeT Ry FULL SCALE CBP HEAT VALUE Sha 645 20143 Tube SIZE PATTERN Neoprene Barrie _ m MATE VAL e 9 ud Reap d Nav j lt 025 STEEL 43 Wig enpa Zu 202413 Ful Size FLAT COLITE AL O22 Fut Size WRAP AROUND PATTERN FoR Shen E IL poq a Rear S i2 292413 Alum SN JOF 67 SECTION II LYCOMING O 320 ENGINE INSTALLATION Long EB STEP V INSTALLING THE GASCOLATOR ELECTRIC FUEL PUMP AND OPTIONAL CABIN HEAT VALVE These two bolts will be accessible from inside the centersection spar box Plumb the electric pump to the outlet of the gascolator with 3 8 dia soft aluminum tube This tube must be bent such that it clears the aileron pushrod It can not pass between the aileron pushrod and the firewall but rather should curve away from the firewall
20. STACK LATER I THEE BAFFLES ARE KOT KEG UITEED Horo Are OA To O 5 To CARE Hear 8 VALVE Heat rise due to carb heat test SOM conducted on Long EZ N26MS dai we DEE February 18th 1981 nu Boo Ambient air temp at the air eer BRock Ex man sr PARALLEL re filter 65 Air temp few measured at carb inlet At 1500 rpm 168 F At 2000 rpm 7 At 2400 rpm 154 F IL pa 5 Long 5 SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 Baffles before installing neoprene lips Note lip to seal around alternator and silicone sealant Note Exhaust support attached to the baffle bolt Breather Bond a flattened alum tube to cowl stiffener Attach a D x 1 8 wall tygon plastic tube from it to the breather SN JOF 67 ENGINE INSTALLATION riy NM x Ld Use these photos to determ top cowl and 24 bottom cowl note the 4 screws and exit scoop for 16 optional oil cooler installation The oil cooler is held in place by 4 10 screws amp nutplates The exit scoop is held on the cowl with 4 pop rivets 2 ine spacing of screws and cowl flanges approx DIL COOLEN i PRO A ml L SR t W 4 Na E Note sliced neoprene baffle lip and carb heat hose routing This hose is bound to the engine mount using a 1 wide strip of neoprene asbestos material to prevent the safety wire from cu
21. cause the wood in the hub area to crush This could crack the finish and allow moisture to enter the wood and will reduce the drive torque capacity of the installation Check track of the blade tips by rotating the prop past a fixed object mounted on the floor Prop tips must track within 1 16 of each other when the installation is completed Protect your prop by waxing with a good quality paste wax and place prop in a horizontal position when parked Inspect and check prop bolts for tightness at least every 100 hours or annually More frequent inspection may be necessary when climate changes are extreme Properly cared for your wood propeller is a safe and reliable part of your airplane SECTION II LYCOMING O 320 ENGINE INSTALLATION Long 5 STEP XI COOLING BAFFLES We have provided full size pattern drawings to assist you to make the baffles to direct cooling air to the cylinders on your engine These drawings are on pages 22 29 Note that for the forward and aft baffles you will need to glue 3 pages together to get the full size baffle due to paper size While it is possible to make these two baffles in one piece you would find it much easier to fabricate them in 2 or 3 pieces Join them at the narrowest point by a allowing some extra material 0 6 overlapping and riveting them together with no prop rivets The baffles are bolted to the engine wherever a hole is shown and further secured in place by applying a gener
22. emel and clear holes through the instrument panel and front and back seat bulkheads or use the holes cut In Step I Now drill a hole in the firewall directly below the hole drilled for the control cables see page 13 and be sure to carefully deburr all sharp edges in the firewall so that they will not chafe your wiring Now thread your instrumentation wiring and direct reading lines if used through the instrument panel both seat bulkheads and the firewall Locate your wiring bundle against the left fuselage side making sure that there is no interference between the pitch trim cables or the landing brake handle and associated cables SN JOF 67 Master Power Voltmeter Internal Battery Voltmeter Charging Status Backup Restore Measurement Units Setting Messaging Alerts Multiple ADAHRS Manual Switchover Multiple ADAHRS Auto Switchover EXTERNAL DATA INTERFACES USB Thumb Drive Firmware Updates Altitude Encoder NMEA Input position time speed PRIMARY FLIGHT DISPLAYS Split Screens Synthetic Vision Land Synthetic Vision Oceans Synthetic Vision Lakes On Off Toggle Synthetic Vision Artificial Horizon Airspeed Indicator Airspeed Trend Vx V y Markers Altimeter Vertical Speed Indicator Artificial Horizon pitch lines roll scale chevrons Angle of Attack Turn Rate Ball Compass Heading Compass Rose on Horizon GPS Ground Track Pointer Outside Air Temperature True Airspeed Density Altitude
23. ements are 3 8 24 bolts conical mount 220 to 320 inch pounds 7 16 24 bolts dynafocal mount 430 to 580 inch pounds EK0QU p BLE Hose CAT DR SCAT ALE 2 5 DIA Host Note or you can substitute a Brock vely 13 FLANGECAUTION Make certain that the outer cord and inner wire are both trapped under worm gear clamp exactly as shown If this is not done the wire can unwind and collapse resulting in engine failure Carefully examine page 13 This drawing is not to scale but clearly shows where to position the above parts on the firewall Disregard the drawing showing position of gascolator fuel pump and wire bundle on page 21 8 Section 1 although the method of mounting the gascolator is the same The gascolator is hung from the firewall such that you can easily reaching through the cooling air scoop and drain the gascolator during pre flight inspection The 3 8 dia aluminum fuel line from the center of your fuel valve see section page 21 5 should come through the firewall just to the right of the throttle carb heat and mixture cables Drill a 2 dia Hole through the firewall push the fuel line through Pot the fuel line generously into the hole with RTV silicone rubber Mount the gascolator as shown on page 13 using two AN822 6D elbows screwed into the gascolator two clamps MS21919 DG11 two AN3 17A bolts with AN960 10L washers and MS21042 3 nuts and two 3 8 O D x 3 16 1 D and 1 l
24. es 1 16 dia through the firewall and make a loop of 0 41 stainless safety wire through the holes as shown at each corner Cut four lengths of 3 8 screen door spring and install the air filter and valve assembly with the springs holding the valve and air filter tightly against the firewall at all four corners SECTION II LYCOMING O 320 ENGINE INSTALLATION Long EB STEP IV INSTALLING THE CARBURETOR AIR FILTER AND HEAT VALVE Before proceeding with air filter installation if you do not have the CS123 bushing and CS124 belhorn installed you should install them now section 1 page 16 5 You can obtain an air filter from your local auto parts store A Purolator AFP 117 or and A C 448C or similar filter will work fine See page and locate your filter as low as far right as possible on the right side of the firewall Be sure that there is no interference with brake lines or rudder cable or belcrank Use a felt tip pen and mark around the filter then set it aside CLAM see pace MOTE TABS AA ml ET Ci BE SUBST Tro Fot TUE WELOS VALVE Ste AT THE 2 Pesition 6 047 4 JETS Murza DES ge SE Bwus525 pR O a u 35 5 4832 Char Za i 8 awh zie VALVE BEID oe The 20 73 BGA 1 EER uEED SHAFT bere fe Par s Mer SEAL a 1 PLATE Alum PLATE 14 5t 1 04 Th EN HEAT VANE SEAL 2RESUIEED Rete vaca mur 5 U
25. etrate the firewall for chafe protection and to seal the firewall Your cables will be too long still coil them up and tape them to the firewall so they don t get damaged Do not bend then too sharply KNOB Prego KNOB DIA Mir a BEND AS Ka NT COLSIT CAB HEMT WATE Test BLACK MITRE RED A SQUARE OR SPKED KNOR roe MIXTURE PREFERTCED I OPTIONAL oS e FIT Bond W CARVE OST J Fox OV 5 IN MACRO Ti ou THYoTTLE ig DIR Wyse HOLE ih BRACKET supports Wik WASHER SOLDERED TO MUSK IRE ACTIVATE Suomen AT Lows THRSTILE To Ae KT ABOUT THE LE KNOE From IBLE EwWACKET TO MOD PACEO SWITCH SwoiTCA MOUNTS LOTTA SCORE SJ INSTE ustu PANEL ME E 19 STRAMD STEfL CABLE TERMIN LYCOMING O 320 ENGINE INSTALLATION SN LE GR EL ry fod AD ALL ADA 8 QWET THRO ARM Te Long EB SECTION Il STEP 1 INSTALLING THE THROTTLE QUADRANT The throttle quadrant shown is an off the shelf unit developed and sold by Ken Brock Mfg We have provided drawings for those of you wanting to homebuilt the Brock unit Refer to sketches shown here and to page A1 Section and locate and mount the throttle quadrant to the instrument panel Use your dremel to clear a hole through the front seat bulkhead and rear seat bulk head as re
26. hese to the aft face of the centersection spar and fuselage both top and bottom edges as shown Spacing should be the same as the screws or camlocs approximately 9 blocks along the top cowl and 10 blocks along the bottom cowl Position these blocks so that the cowl lip rests on the blocks the lip is level with the spar or fuselage as shown SECTION II LYCOMING O 320 ENGINE INSTALLATION Long 2 Oil pressure sender Install as shown The sender mounts to an engine mount tube using two Adel type clamps MSS21919 DG10 bolted together one around mount tube and one around the AN910 1D coupling The orifice fitting is normally supplied with the engine It has a tiny hole which prevents massive oil loss in the event of hoze or sender failure TT W I ck 4277 P gr 491 amp ANO Jn F irriuGs Ceu firme SENDER 3060 ig Kecnesrec 360 Soy vpo Photo of carb and carb controls bracket View from aft looking forward Note The throttle clamp block is too far to the left on this photo Make yours exactly per page 16 to assure positive throttle actuation in the event of spring failure Note The black plastic does not go into the clamp blocks STEP IX COWLING INSTALLATION Long EZ cowling halves are available from Long EZ distributor These parts will require some additional work as part of the installation on your airplane You will have to trim the outboard ends of the cowling halves to fit the wing roots
27. in cooling the oil in the sump In addition the 10 320 has a fuel injector The fuel injection system schedules fuel flow in proportion to airflow Fuel vaporization takes place at the intake ports 320 CUBIC INCH ENGINE SERIES According to specific engine model configuration HEIGHT WIDTH LENGTH DRY WT MODEL RATIO HP RPM TBO IN IN IN LBS REMARKS O 320 A 7 00 1 150 2 700 2 000 22 99 32 24 29 05 29 81 271 279 Conical Mounts NOTE O 320 A1A Same as O 320 model designation change only In most cases the O 320 case will be machined to accept a mechanical fuel pump One more consideration is provision on the engine to be able to install an oil cooler A relatively small percentage of these engines may not be machined to accept oil coolers The original Long EZ N79RA has a Lycoming O 235 C2C engine and is not equipped with oil cooler On a hot day during an extended full throttle climb the oil temperature is marginally acceptable We do recommend the installation of oil cooler IMPORTANT The scope of these installation drawings does not include educating a home builder in all the disciplines leaned by an A amp P mechanic to allow him to work on aircraft engine installations Thus if you are not an A amp P mechanic you should have an A amp P install your engine and accessories or at least have an A amp P inspect and approve the work SN JOF 67 eight inches or so Pot the cables generously with RTV silicone rubber where they pen
28. it the top cowl to be sure the neoprene asbestos cylinder head baffles rest nicely against the grey duct tape on the plywood Remove the top cowl and sand the inside adjacent to the grey duct tape Layup 2 plies of BID at 451 and allow to cure Knife trim to the edge of the plywood at the appropriate time and allow to cure Carefully remove the plywood pieces and sand the shiny surface of the glass rib and adjacent to it on the cowling Layup 2 plies of BID at 45 Knife trim to the previous glass layup and cure This gives you two permanent fiberglass ribs in the top cowl that the cylinder head baffles seal against which allows you to remove the rocker covers for periodic maintenance without disturbing the baffling With all the baffling in place carefully check for any potential leaks AI possible leaks should be sealed or you may have unacceptably high cylinder head temperatures Long EB SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 IL psgz uf lu Prywoor TEMPLATE T THESE OVEIZIAP mo de Hoes Fok pep RiveTinG BAFFLES TeeEeTHEe Typic4e A MAKE v PIECE RREN caw BE ONE PIECE LEFT REAR CYLINDER A 1 A J O AH LOC AALG Ip p J Aa 436 Pue CTYPY L uj VIA gt 0 Cx 2 x 4 n SS O M xo u G Fs z
29. kpit Fresh clean air must be brought into the heat exchanger do not use the high pressure cooling air in the cowling for cabin heat This air could easily be contaminated by any small exhaust gasket leak or undetected exhaust leak Because the possibility always exists of carbon monoxide getting into the system it is highly recommended that you install a carbon monoxide indicator in the cockpit Route a 1 dia cat aero duct hose from the cabin heat valve forward across the aft face of the back seat bulkhead to the right side of the fuselage This hose should run forward along the fuselage side to the instrument panel Be sure to secure the hose so that it does not interfere with the control sticks pushrods etc Do not allow this hose to come into contact with the fuel lines which also run up the right side Allow a minimum of 77 clearance between the hose and the fuel lines LYCOMING O 320 ENGINE INSTALLATION OFONAL la Dia CAT QA car nose COR SCAT lt 0087 137 d OD x 5 HLum THEE Long EZ SECTION Il OPTIONAL CABIN HEAT VALVE f4 q LOCATE NEAL HK INLET TO ASSURE FRESH Ai Source in CASE OF ExnAusT WEAK NOTE care HEAT 15 RARELY NEEDED WITH Lyc 0 235 CAEID HEAT is OF UMEN CARE HEAT L SELECTED 2 pascar AELOPUCT NOSE Eorrom CoL DETAIL A The carb cabin heat exchanger shown on pg 33 is available as an integral part of your Long EZ exhaust s
30. l All of the instrumentation called for in this step is available through a Long EZ distributor Recommended Instrumentation Option 1 Analogical Cylinder Head Temperature Rochester gauge 3070 61 or VDO 310 909 Sender 3080 14 or VDO 1323 701 Oil Temperature Rochester gauge 3070 62 or VDO 310 014 Sender 3080 37 or VDO 8323 057 Oil Pressure Rochester gauge 3050 54 or VDO 350 044 Sender 3060 18 or VDO 8360 004 Fuel Pressure Rochester gauge 3050 58 or any direct Sender 3060 17 reading pressure gauge Tachometer Carr 2 CT42 DS Carr 3 CT 43 DS First mount your engine instruments positioned as desired on the instrument panel Any direct reading instruments must have lines at least 10 feet long A mechanical tachometer is not really practical due to the long heavy cable required The tachometer recommended above operates electrically through a small tach generator which screws directly to the tach cable mount on the accessory case of your engine These Tachometers have proven to be reliable and reasonable accurate A magneto powered tachometer can be used but do be certain that there is no way that a magneto failure could fail one or both magnetos If you have a starter a standard key type on left right both start switch works well Without a starter two miniature switches micro 8A1011 or Alco MTF 106N mounted as shown on page A1 or where desired are required With all these mounted take your dr
31. mb Of course the 2 77 dia opening can be varied to suit People living in extreme climates may need a large opening in summer and smaller or completely sealed opening in winter FINISHING UP Install your prop 3 prop extension and spinner Follow the instructions supplied by the manufacturer Do not install a prop extension without drive lugs to locate in the forward face of the prop Proper torquing of your prop bolts is important The prop is driven mainly by the friction developed between the prop hub and the engine flange or prop extension Extensive testing has shown that wood props generally should be compressed about 0 006 per inch of hub thickness That is to say that a Long EZ prop normally about 3 thick at the hub should have the bolts torque up such that the wood in the hub is compressed 3 75 x 006 0225 Since your prop bolts are 3 75 x 24 threads you can readily figure that you must turn each bolt 54 of a turn after the front face plate the prop hub and the prop extension flange are in contact 0225 x 24 0 54 turns the difficulty here is in knowing exactly when the prop and flanges are in contact particularly if you have bolts that are tight in their holes Generally you can achieve the same prop hub compression assuming your threads are clean and dry and in good condition by torquing your 3 8 dia bolts to approximately 200 inch Ibs 25 inch Ibs Caution over tightening prop attaching bolts will
32. o drill through the steel tubes Be very careful here it is very easy to have the drill wander off and elongate the holes Best procedure is to drill the holes undersized then drill or ream them up to size Drill 7 holes per extrusion as shown Use your long drill bit to drill the horizontal holes due to drill motor clearance Install ANA 14A bolts through the upper extrusions and brake arms don t forget the CS75 steel bushings use AN4 13A bolts vertically through both upper and lower extrusions and AN4 12A horizontally through the lower extrusions Use AN960 416 washers as required and MSS21042 4 nuts BA BRAKE ARM FIREWALL GERDES Mover 049 FWD BRAKE 87 CYLINDER 5 CS13 Au4 158 ANSA IORS 3 32 STEEL CABLE D SEE CHAP Ilo RX 21 5 5 N PX n X 8 2 G mee 3 An 2 A Biver i MS21042 4 LOWER ENGINE MOUNT TUBE CS 3 THIS IS FoR CABLE To Kupper SEE CHAp IG G ANGTOADY b Sonim 5 CSS Mu CABLE See CHAP Ib SN JOF 67 Next fabricate the carb heat and air valve shown below and on page 9 This part is available prefabricated from Ken Brock Mfg Locate your air valve over the outline you marked of the air filter so that the four corners over hang it roughly equally Mark the location of each corner on the firewall Check again for possible interference with brake line or cables Drill two small hol
33. ong spacers Be sure to orient the gascolator correctly for fuel flow in vs out If your engine has an MA3 carburetor it will not have a built in accelerator pump The MA 3 SPA carburetor has the pump Without an accelerator pump particularly in cold climates the engine can be very difficult to start This can be remedied by installing a primer The primer pump should be installed on the instrument panel if you intend to hand prop start Fuel for the primer should be taken from the top of the gascolator using an AN816 20 1 8 dia soft copper tube should be used and you should drill a dia hole through the firewall and pot the 1 8 copper line in RTV silicone rubber The electric boost pump is required on your Long EZ and should under no circumstances be omitted Mount it where shown on page 13 using two AN3 10A bolts AN960 10L washers and MS21042 3 nuts If you cut out the oval shape lightening hole in the plywood firewall bulkhead you will need to position a small piece of plywood in the void in the area where these two bolts go to secure the electric fuel pump Be careful not to drill trough the firewall into your centersection spar cap That would spoil your entire day Sree Spaced ANT 3BSA Gers 4 Rear Eer TYA Fog g Reg D WELDED Pyracoazat Awe Eydna E CRANK CAS DYWAFOCAL DETAIL SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 QA O D x e OUT ALUM
34. ous bead of RTV silicone the red or silver high temp RTV is best and is generally available at auto parts stores along the edges of the baffles wherever they touch the engine or to seal imperfect fits and as an anti chafing material Fabricate all the baffles shown using 025 thick 6061 T6 aluminum sheet The inter cylinder baffles are fitted into place and secures in addition to high temp RTV by safety wiring them down to the stiff piece of music wire which is bent and fitted between cooling fins as shown OAS ALUM INTE RCYLIN PER rr BAFFLE 253 DA aec wite With all engine baffling in place install the cowling one half at a time and measure the distance from the top of the aluminum baffles to the cowl This dimension should be from 4 to 4 except along the cylinder head baffles where it should be to 1 Make up neoprene asbestos strips as shown in the photos and rivet them to the aluminum baffles as shown With the top cowl in place mark the inside surface of the cowl adjacent to the outboard edge of the cylinder head baffles This mark will help you locate the two glass baffles that have to be lay up into the top cowl See page 22 for full size templates for these baffles Lay these out on a piece of 1 8 plywood or something similar cut them out and stick grey duct tape to the out board faces of the plywood Now Bondo these pieces into the top cowl along your marks When the Bondo is hard trial f
35. quired Drill a dia hole in the firewall as shown on page 13 Run the cables along the left fuselage side at W L 11 as shown routing them through the holes in the bulk heads and firewall Be sure and deburr the hole in the firewall well Organize the 3 cables to lay flat against the fuselage side and use short strips of grey tape to hold the cables temporarily in position You can run the cables over the plywood blocks L B 17 and PT1 that the landing brake and pitch trim handle mount to or you can route out a groove in these two plywood blocks to get a lower profile and straighter cable run Now use a small blob of dry micro to bond the cables to the fuselage side and layup one ply of BID over the dry micro and cables Do this every DETAIL C Boot THESTILE DwiLL to BEnb Music la EE 55 deg Lia Fee pub TA SERT IST HOLE CLOSE PEPXIMIT Y Dr MN TUEE GUADITAST COMMIS THE MUSO La FE SN JOF 67 This may require routing the wire bundle through the instrument panel then down towards the floor until aft of the landing brake pivot Use grey tape strips to temporarily hold the wiring bundle in place then pot the wire bundle to the fuselage side every 8 or so with RTV silicone Do go ahead and include a couple of spare wires in your bundle this can TRRSTTLE FRICTION H ARIDUARE BEVUE SPRING WASHET Wi E THIS BOLT ES THRU ALL N960 3 CONTROLS IF 3 ARRE USED USE IN SETS ac ONLY 6635 Si BELVI SPRWG WASHER
36. r a minimum of 24 hours flip the fuselage over and repeat the above for the lower engine mount extrusions with the exception that the lower extrusions do not get the additional pieces of extruded aluminum angle etc Allow the lower extrusions to cure with the engine mount clamped in place This assures you of a perfect fit between the welded engine mount and the aluminum extrusions Aw4 13A SECTION II LYCOMING O 320 ENGINE INSTALLATION Long 2 STEP III INSTALLING THE ENGINE MOUNT Depending of the engine we will require either a conical or dynafocal engine mount Both of these are available as welded up bolt on assembly from Ken Brock Mfg or others At this point we will assume we do not have our engine mount aluminum extrusions installed into the fuselage Cut the L shaped holes through the firewall in the correct places Drill a couple of holes and use a saber saw or a dremel and pin router Slide the four 8 long aluminum extrusions into place and verify that they are correctly located with respect to butt lines and water lines Make the four wood wedges called out on page 14 4 section Now cut two pieces of the same aluminum extruded angle 1 6 long Cut some 1 8 thick aluminum sheet into two pieces 1 6 x 2 Carefully examine the full size drawings on this page to familiarize yourself with how the top extrusion mount assembly goes together You should bolt the 1 8 x 1 6 x 2 pieces of aluminum
37. re to have a right angle drill adapter the small aircraft type is best and is available from a distributor A 10 long drill bit is required to drill in the engine mount and works well to reach in to drill through the extrusions and centersection spar See section page 14 4 for bolt hole locations and bolt sizes Flip the fuselage back cover and drill and bolt up the top engine mount extrusions per Section page 14 4 lt 7 EB SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 STE Tu Z SPACER Le DW X Atl d F WELPEP Mounr ANC 43A Bour E 2 Rutter AN ZG C t Tu SHINGS LOS HE Exproper view oF A LYC 0 235 CONICAL Mounr ANP ASSOCIATED PARTS We are using a conical engine mount because the Lycoming 0320 used on this airplane require a conical 8 17 G WASHER pics KOS NE P ua 8 52 4 6 5 5 W L RW 5 SS Comp ETE ON CcAL ENGINE mMounors ALE AVAILABLE FRom A LONG EZ DISTRIBUTER F S 133 3 58 120 Ream ro As AFTER WELDING a o gt x 120 WALL ZK Long 4 pres c 5 Je View FRom AFT 258 o x O44 WALL b TUBES d i ES 33 6 TI WL 9 B L 5 15 N KL 050 GUSSET 2 W L ILI f la 1 AL IS PE B L 7 35 INBD T i KA 3 F L ve 1 Jg o x 044 WALL cl
38. rethane foam and excess wood blocks with shiny grey duct tape for a good release Now do the layups as called out above for the Long EZ cowl including the inside lip t o centersection layup Pg 18 amp 19 CoU NT LE darsi Tor Cou AM n MENT ING LIP MicED SN JOF 67 Now install the exhaust system available from Ken Brock Mfg and measure from the wing root trailing edge to the exhaust pipe each side Transfer that to the bottom cowl and cut out a hole large enough to clear the exhaust with aluminum of around the pipe to allow for engine shake STEP XII OIL COOLER The prototype N97RA does not have an oil cooler installed During a full power climb to 12 000 ft the oil temperature will climb almost to the red line During cruise flight oil temp runs between 200 and 2202 which is marginally acceptable A second Long EZ with a flush NACA inlet was found to be unacceptable for oil temp temperature although cylinder head temperature was excellent This air plane has been equipped with an oil cooler which is simply bolted to the lower cowling on the left side and a 2 dia Hole was cut through the cowling directly under the oil cooler This allows high pressure cooling air to escape through the oil cooler A small reverse scoop fabricated by laying up 3 plies of BID over a carved piece of urethane foam is riveted to the bottom cowl This system provides good oil cooling 1809 2009F at cruise and 2209 2309F in a long cli
39. roots This last layup is an upside down operation but is easy to do particularly if you do the 5 ply layup off the airplane on a piece of visqueen plastic first then while it is wet lift the visqueen and 5 ply layup and place it in position under the cowl edge lapping under the edge of the wing root Squeegee it well through the visqueen and allow ure The plastic will easily peel off later bp SVCKS Boubobo In PLACE Linge fur BIP 12 Cow REINFORCEMENT GREY TAPE S p v Bip args RELEASE FLANGE LAYUP e Ipv Ee w w Neo Remove Cowl hayup THe lpuy Bip GS on THE ourse AS SHOWN When all top flanges are cured drill 130 holes through the flanges and cowling where you will later on install screws or camlocs This will allow you to cleco the top cowl back into exactly the position it is in now after you have removed it Knock the 2 x 2 wood blocks off the centersection and fuselage and remove the top cowl Repeat all of the above and lay up the flanges around the bottom cowl This entire operation can be done without turning the airplane over If your work area does not allow you to install both wings at the same time you can install one wing lay up the wing root flanges for top and bottom cowls remove that wing then install the other wing and do the wing root flange layups on it It is a big help to Bondo a rib to the aft face of the cen
40. s 2 9 Pin DIN Connector for the SkyView Networks 2 USB Connectors 1 Ethernet Connector currently unused DETAILED FEATURE LIST HARDWARE SV D1000 10 Display SV D700 7 Display Backup Battery SV BAT 320 ADAHRS First SV ADAHRS 200 ADAHRS Additional SV ADAHRS 201 EMS Hardware Module SV EMS 220 GPS Receiver Puck SV GPS 250 Autopilot Servos SYSTEM SOFTWARE Clock Local Clock Zulu Screen Dimming SN JOF 67 wedges to the longerons and adjust the number of plies of BIDt o obtain a good fit add whatever plies are necessary but do not end up with less than 7 plies under each extrusion When you have an acceptable fit dry unclamp the engine mount remove the top extrusions and dry glass and thoroughly sand the corners between the centersection spar and top longerons Glue the wood edges in to position using wet flox Layup the 10 plies of BID or however many it takes into each corner sand the aluminum extrusion completely dull using 220 grit wet or dry Paint pure epoxy on the extrusions and install them carefully so as not to disrupt the BID glass Press them gently into place and clamp the engine mount back into position on the top extrusions If you have done everything right the top extrusions will now be held in position by the engine mount Fill any voids under the extrusions wood wedges centersection spar firewall or longerons with flox and allow the whole thing to cure undisturbed Afte
41. tersection spar to define accurately the wing root trailing edge of the wing that will not be installed while you are installing the cowling Be careful when you are removing the cowling halves not to peel the flanges up off of the spar fuselage or wing roots With both cowl halves off the airplane you need to layup one ply of BID under each flange laping down onto the spar or wing as shown Of course you must thoroughly sand the shiny surface under the flanges and wipe a small amount of dry micro into the corners to give a smooth transition as shown or better yet use peel ply before the 5 ply layup When everything has cured trim all rough or sharp edges and drill out the 30 holes to 10 for AN507 screws along the leading edges of the cowling and install K1000 3 nut plate s on the inside of the cowling lips Install screws or optional camloc along the outboard edges and trailing edges of the cowling Camloc part numbers are as follows Stud 4002 6 or 4002 7 depends on thickness of your cowling lip and flange Grommet 4002 N grommet retaining Snap ring R4G receptacle 214 16N SECTION II LYCOMING O 320 ENGINE INSTALLATION Long EB Top View Borrom wi 5 ene p LITH CowL GREY TAPE THis AREA oH Borrom COWL SAND on Top CowL STAND COWLING ON ITS TRAILING EDGE Tape TRAILING EDGES TOGETHER JIG LEADING EDGES TO 1 BID Y SEcreeo 4
42. test cylinder is determined leave the probe in it All cylinders on N79RA run within 209F of each other If you have a wide variation the probable cause is mixture distribution Follow your engine service manual and route the ignition wiring spark plug leads to each plug Snug the plug caps shielded harness only using a wrench don t over tighten Be sure to guard the ignition wires against chaffing on the cylinder cooling baffles using rubber grommet as shown The exhaust gas temp probe should be installed on number 4 cylinder exhaust pipe Ge o S MIKO 3 18 AWG wie SECTION II LYCOMING O 320 ENGINE INSTALLATION Long 2 STEP VII ENGINE WIRING AND CONTROLS It is helpful to have an assistant to verify control positions and travel in the cockpit while you work on the engine First make all the metal parts shown page 16 Install the throttle mixture bracket on carb studs This bracket becomes a gasket between the carb and engine and requires two normal gaskets one each side when installing the carb The small tab on the aft end of the bracket should be bolted to a 063 x 6 alum strap The strap should be bolted to an oil pan bolt Apply additional damping by bonding the bracket to the oil pan with silicone rubber RTV Next run your mixture throttle cable out and around to the right and mount to the bracket as shown Be sure the clamps aim the cables directly at the actuated arm with as little flexing
43. tle quadrant assy Long EZ Spinner VESPI Prop Plate KM01068 3 inch Prop Extension KM06018 Exhaust System with heat muff BJX IHM Cabin heat valve optional Carb heat valve assy VECHVA Electric fuel pump EFP Carb Heat flange optional VELY13 Long EZ Lyc O 320 Conical engine mount 2 Steel Bushings LL 3 2 Alum Bushings LL 4
44. tting into the hose i E Ae fc E dree Pa iain Oil cooler on left side Note K 1000 32 nut plates installed with rivets rn spring Long EF SECTION LYCOMING O 320 e THIS GAP BILLED MOUNTING BEFORE OLO SHORT Couwrl LA YOP Jigging cowl to fuselage and centersection spar using clecos and wood blocks If cowl does not fit satisfactorily it can generally be urged into place after application of heat from a hair dryer or industrial heat gun x vor LS AMM la e This photo shows installation of mixture arm cable and retu fiberglass carb inlet elbow and fuel pressure sender vi i h Oy SL L SECTION LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 Plume we Scyemaric Anp Hers INFORMATION ON THIS PAGE SUPERCEDES ANY INFORMATION GT P Z LonG Ez S 3 Z log HP PN Fu amp L VALVE AN 819 6D TUBE A ALUM TURE lt SS 4 4 4 Ki EFP 22 2 KE Lodi AN822 6 2D 49 9 AC 6470069 AngII 6D 4 gt AEROQu P 6 AN 8 25 303 6 ENGINE ER DRIVEN 3 MIT mecuan e 4L D g o p SeFr FUEL pune u Y ad Aum TUBE mr lt Yg AN C 6 CY Aum TUBE Te FUEL
45. ur thumb and finger and verify that you have full mixture travel at the carburetor when the mixture control is cycled in the cockpit before you swage the sleeve If you don t get it perfect an adjustment can be made at the housing clamp Tighten the bolts on the cable housing clamp Add a dab of silicone rubber SN JOF 67 ADD PLY Bip 45 tape on the inside trailing edge of the bottom cowl as shown Jig your cowling on the floor trailing edge down with the trailing edge taped together with grey duct tape and the leading edges opened apart 8 as shown Cut 10 strips of 459 BID glass 4 wide x 15 long and 2 strips of BID glass 3 wide X 15 long Now layup a 5 ply BID glass rib into the trailing edges of the Cowling Allow this to cure then drill 3 30 dia holes evenly spaced along each trailing edge through the bottom cowl grey duct tape and cured trailing edge rib These holes will be used to cleco the cowl valve s together when jigging the cowling to the fuselage Later on they will be opened up for screws or camlocs Now pop the two cowling halves apart and sand the 5 ply closeout rib and top of the top cowl and layup 1 ply of BID as shown After cure trim the closeout rib to 1 6 as shown Thoroughly sand the top and bottom aft edges of the centersection spar also around t he aft edge of the fuselage Sand inside the wing roots top and bottom Cut some short pieces of 2x2 lumber about 2 long Bond t
46. your Long EZ The cowling on the prototype N79RA is a VariEze cowling In order to find out which cowling you may have measure the length of the top cowl along the centerline as show OLD cowl 42 0 NEW COWL SS oY 22 The VariEze and early Long EZ cowl is 32 The new Long EZ cowl manufactured after December 20th 1980 is 32 7 The VariEze cowl is also approximately 9 wider than it needs to be for a Long EZ This means that it will be necessary to reinforce this area for screw or camloc mounting Sand the inside face and layup 4 ply BID reinforcement on the inside of the cowling halves 2 wide and 4 places as shown After this cure trim approximately 9 excess off the outboard ends to fit your wing roots 4 pues BID LE ON INSIDE OF Comi W amp teze ok i ie RE Tece etx i 1480 Lene Ec Trim here Cowl TOR won Y Top View Coul With the old style shorter cowling it will be necessary to space the cowl halves 0 7 aft of the firewall and centersection spar Use wood bloc k Bondo ed to the aircraft t hick enough to extend aft far enough so that you can cleco the cowl to the aircraft see photos on page 35 After the cowl is jigged and cleco ed in to place the 0 7 gap should be filled between the wood blocks with scraps of urethane foam These can be jammed into the gap and sanded level with the cowl lip Then cover the u
47. ystem Ken Brock Mfg sells these parts and they are welded up on the exhaust and pressure checked for leaks prior to being sold If you intend using the heat exchanger to provide heat in the cockpit it is absolutely mandatory that you install a fresh air ram scoop in the lower right cowling and connect it to the aft 2 dia tube on the heat exchanger This clean cold air then is heated up by the hot exhaust and is forced forward by ram pressure through a length of scat red high temperature aero duct hose to the carb air heat valve as shown This is the source of carb heat if or when required If you decide to install the optional cabin heat valve as shown on page 9 you should cut a 1 77 dia hole in the carb air heat valve and install a short 1 dia tube welded or sealed as shown This is connected to the cabin heat valve with cat black aero duct hose Thus you have a clean source of hot air for the cockpit Long EB SECTION II LYCOMING O 320 ENGINE INSTALLATION SN JOF 67 HEAT MUFF Full SCALE EFHAUST Petre wtp ALL BI x ANM PRESS URE TEST For atmo LEAKAGE Oi STAMILESS RA 5 29 255 O29 STAINLESS Bock 5 7 uPPORT TAG Osa O64 TUBE Ww TUA AR DETAIL A pq 32 METE Muff s aS Dia INSTALLED ONLY a ISIDE VIEW op MIGHT EXHAUST DIR 5 7 5
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