Rapture

The cabin heat air intake duct has now been fully bonded to the lower cowling and the photo below shows the scat hosing geometry from the intake air duct to the heat sleeve around the exhaust pipe and then out to the cabin vent. Fasteners yet to be applied as this was a trial fit.

Earlier on in this thread, discussion arose about the proximity of the oil filter to the exhaust. Here is a photo of the clearance that we have with our installation. We will look at whether any insulation is required in due course. There is adequate clearance to allow the filter to be removed with the exhaust in place. The composite channel that you can see in the above photo is being bonded to the inside skin of the lower cowling. This is an air duct for cabin heat. It extends from the intake at the front of the cowl back to the heat muff around the exhaust, with scat hose connecting the composite duct to the muff inlet. The radiator is to be installed in the forward lower cowling. Our radiator is close to double the area of the standard Rotax cowling. The radiator mounting frame is attached to the lower cowling by 8 fasteners, allowing the fasteners to be released to remove the lower cowling without needing to disconnect the radiator. The engine mount turned out so well. I keep admiring it every time I get sent photo updates about the installation. All in all, it is coming together nicely. We are starting to get excited to test fly our 109hp J160.

Thanks BrendAn. We are really happy about how the mount turned out. It all fits nicely into our cowling. Most of the accessories were pre-installed to make sure they all fitted in. Now with the engine in its final location, the accessories can be installed around it. The overhauled landing gear will be reinstalled next week so we will then have it sitting on its gear as well.

More progress. The engine mount turned out really nicely with prop flange location, offset etc. all being extremely close. Exhaust and accessories to be installed now. The paint shop for the fuselage isn’t too far away…

Our prop spacer arrived a couple of days ago. Now we can really make headway with the mount.

Please guys. Going off topic will really devalue this thread for folks actually wanting good information about the Zonsen engines and installations. i shall respectfully ask an admin to moderate this thread to remove junk. Please start your own threads for sidebar conversations.

This. We appreciate the observation about the proximity of the exhaust to the oil filter. Appropriate measures to reduce or negate the proximity of the exhaust to the filter are being adopted. Future posts will show these initiatives.

The next instalment in the CA510 110hp installation into a J160 is a bit overdue but here it is. The engine will require a 3” prop extension to fit nicely into the cowling. We are waiting for the extension to arrive from overseas. Once it does, the engine location will be confirmed and the mount will be final welded. In the meantime, the exhaust system has been welded up and looks very nice. The photo below shows the exhaust system mounted to the Rotax we have been using for mocking things up to keep the new Zonsen engine pristine until the final installation is ready. Hopefully the prop extension will arrive soon (it has been shipped so we are waiting for it to arrive) so that we can finalise the engine mount. Bolly is doing a special prop for us which we are excited to trial with this airframe/engine combination. The fuselage work is essentially completed but awaiting painting. The wings have been painted and are ready to go back on the fuselage. Once the engine and accessories are mounted, we will have throttle cabling and instrument wiring to do and then we are pretty well done with the installation.

This one is 19 registered so is ok. For S-LSA Jab 160Cs, we will develop a MARAP package to be submitted on an individual basis for approval to allow these aircraft to be fitted with the Zonsen engine and continue to be used in commercial operations. We will do the engineering analysis for a standard FWF conversion that we will offer the package for. This is all dependent on folks actually wanting this conversion. We will determine that demand once we have an aircraft that we can demonstrate. If no one wants it, then we won’t go to the hassle or expense of developing the full MARAP package.

Yes, the oil cooler is enhanced also and we will work out the required airflow.

Sorry Brendan, this post slipped through the cracks. The focus has been on obtaining and planning for the installation of the FWF engine accessories, as well as installing the fuel pumps adjacent to the fuel tank. We have a new radiator that is slightly larger than the stock one for a 912, since our Zonsen CA510 has 9 more hp and our aircraft is based where it gets super hot in summer. Also, the CA510 is fully liquid cooled, no air cooling of cylinders required so again, we opted for a slightly larger radiator. We have also installed carby heat and that system is partially shown in the attached photo. Last weekend, the engine mount has been mocked up with a view to being welded shortly. All in all, progress has been steady but not much visual progress to photograph. Hopefully, there will be a bunch more progress with associated photos over the next few weeks.

I’ve always used USPS for small items. You can get it with tracking.

We are trying hard to keep the modifications to the J160 airframe minimal so that future conversions are both minimum cost and complexity. The above photo shows that the stock cowling still fits fine. With our 110hp CA510 being fully liquid cooled, we might even be able to plug some of the holes in the stock cowling to reduce some drag.

It’s a very old, junker 912 but is dimensionally correct for the Zonsen installation so is good for the mock up.

While we will shortly be delivering our brand new 110hp Zonsen CA510 engine to the aircraft, an old Rotax is being used to finalise the engine mount geometry, as well as to facilitate the installation of the final engine accessories such as radiator, oil tank and cooler etc. When the new Zonsen engine arrives at the airframes location, we will be able to drop it straight in to replace the Rotax. The attached photo shows the Rotax and the associated firewall to engine ring frame mount. A jig will be fabricated from this first (non-airworthy) engine mount from which the airworthy mount will be made. The prop hub has been determined to be in the identical position to the Jabiru hub and we hope to be able to use the original cowling with minimal modifications. Now to plan the installation of the engine accessories.