Cooling System Install

The cooling system was final installed today. Here is the radiator.

The radiator is attached to the firewall at two locations and from the front with a rod which is clamped to the engine mount.

The radiator hose runs from the expansion tank, down into the left side of the radiator. You can also see 5" of hose slit and zipped tied to the main hose for anti-chafe protection from the engine mount. An 8" spring was inserted into the ID of the hose to prevent the hose from pinching at a severe bend.

Here is the hose coming in to the left side of the radiator.

The second hose runs from the water pump down into the right side of the radiator. Again, a spring was inserted and extra hose was used for anti-chafe.

Here is a view looking up from the belly.

Not shown is a 24" piece of 1/2" poly tubing running from the expansion bottle to the overflow bottle mounted on the firewall.

Lubrication System: Oil Cooler Install

The oil cooler is mounted to the front of the engine. Here is a front view of the mounted cooler.

From behind, you can see it mounted to the engine in two of the three locations. The cooler is mounted between two aluminum channels/layers of silicone and sandwiched by four threaded rods. The silicone will dampen vibration.

You can see a gap between the cooler and vertical side of the channel. There could be concern that this will shift and rub metal on metal. Liquid silicone was suggested, but I don't want to risk plugging the cooling area. I will monitor through course of operation, as it eems like it is in there tight.

My kit is missing some oil lines (manual says to be provided by Rotax) so will contact factory to obtain entire updated lines sheathed with fire resistant material.

Install Exhaust System

The exhaust system is installed and complete. Below pic shows all of the components. One half of the heater wrap, shown below, has flange fittings riveted and siliconed to two hole openings.


Here is a closeup of the flange fittings. Heater hoses will later attach here. The aluminum wrap around the muffler functions as a heat exchanger and warms the supplied air and returns it to the cabin.

Here is the heater wrap being installed around the muffler. Spacers are used to optimize fit.

The exhaust pipes were loosely attached to the engine and the muffler was attached to the pipes through a series of springs. My dad assisted while I stretched the springs with a device (handle with small hook) I had saved from stretching springs on my kids' trampoline. Worked slick. Once everything aligned and in position, I torqued down the nuts on the studs connected to the engine.