Well, Since it’s one of the key “features” of the Kitfox, I figured I best try and fold the wings and make sure everything was rigged properly. Also, I had to replace some fuel lines so I needed access to the end of the fuel tanks. Final results, yep, they fold. It’s amazing how easy it is to do it.
So one of the recent additions by Rotax is the recommendation to have a return fuel line from the engine to the tank to ensure cool fresh fuel gets to the carbs. There are a couple of ways that you can plumb that line, but they all share a common requirement. You must put a restrictor somewhere in the line to ensure there is more fuel pressure going to the carbs than going down the return line. This takes the form of a “Pilot Jet” that is installed in either the Banjo bolt, or in the actual fuel T. In my case I was removing the 2 port fitting to go to the 1 port fitting. All I had to do was remove the pilot jet from the 2 port fitting and install it into the banjo bolt. Look at the attached pictures for details of how the jet fits into the system.
Then the actual return line is simply a section of 1/4″ fuel line that runs back to the top of the header tank behind the seat. This gives a slow trickle of fuel back to the tank when the engine is running.
Here’s the latest update from this weekend. I now have the panel installed and all of the main power & electrical system wiring done. Still to go is headset wiring, engine monitor wiring, complete fuel system rebuild. Good times!
Here’s the main power distribution center. Fuse panel, crowbar overvoltage module and relay for alternator feed, filter cap, etc.
Here’s the back of the main panel location, with the switch panel & wiring routing. I used some adel clamps attached to the bottom edge of the panel to create a nice wire chase path. Keep them from being zip tied to the tube structure under the panel.
Here’s a neat idea for your GPS antenna farm. Since the glareshield is fiberglass, they work just great mounted just underneath the dash cover. Keeps them out of the way and securely mounted.
I used a Brother label maker to create the panel labels. The key to making them look nice is to use the black border function. When cut out carefully they blend in great on the light colored panel.
Thought I would do a quick review of the Remote Oil Pressure kit that you can get from Kitfox Aircraft. It allows you to move the oil pressure sender off of the Rotax 912 and back to the firewall to get extended longevity by reducing the vibrations that it gets from the engine.
The kit is very complete with all nuts, washers, screws, clamps, wire, hose, fittings etc. Couldn’t ask for an easier setup. Here’s a few pictures to give you a sense of it.
I also installed a new pressure sender to make sure as mine was a bit flakey at this point. The new ones are much cheaper as they don’t com from Rotax, however they are both made by VDO and look to be the same part. The only thing I did was to move the brass ring over to the new one. Not sure what it’s function really is, but it looks nice! You take a bit of heat with a propane torch to the ring and it releases the glue from the old one. Then just use some RTV to attach it to the new one.
Let the games begin.
This weekend I pulled most everything apart. I started by one by one removing each wire from the back of the panel and electrical bus. By selectively either cutting and removing, or taping and labeling each wire that I needed to keep. Once everything was traced out and clearly understood, I removed the remaining connections and parts from the instrument panel. Then Removing the panel was a small matter of a few bolts at the bottom that held it in place.
It’s funny that as you go deeper and deeper into the project it starts looking like you’ve almost totally dismantled the entire plane. At one point I had to fold the right wing slightly to get the OAT sensor out of the wing root. At least I know that the pin will come out and you can fold the wing back. (better make sure and put that pin back in when I’m done!)
I made sure to keep every part that I was removing, including all the wire and parts in a box so I can weigh all of the stuff that’s not going back in and see what I removed. Mostly for curiosity sake really. When the rebuild is done I will weigh the plane and get a new weight and balance done for the record books.
Here are more pictures of the progress to date. From this point things should start going back in as the project progresses.
