@Q:200 CONSTRUCTION PLANS SECTIONII Addendum to Q2/@:200 Construction Plans Continental 0.200 Engine Installationstep step step step step step Step step Step step 1 um. vie vit. un. ux STEP CHART Construct magneto box A. Use Appendix Sheet #2 as an assembly guide BL Glue pieces together with § min. ©. Cover box inside and outside with 1 Bid. Build up the header tank and set aside to cure, Cut out hole in FirewaTl A. Use template in Appendix Sheet 43 to Find position and shape of cut out. Save template: You will use it to locate engine rmgunts Toca tions, Mount magneto box in Firewall. A. Box should be taped in with 2 Bid tape and flox. BL Install Firexall stiffeners on inside of firewall with 2 Bid. ©. Lay-up a 4 Bid Tocal lay-up over the 4 engine mount, areas, both inside and outside of Tirewall. D. You people wha have changed your mind on engine types and have already installed a header tank have a big problen. You will find it very hard to install the mnagneto box and impossible to install the engine mount bolts with the bolt heads on the inside of the firewall. Since the header tank on the Q-200 is smaller anyway. wwe would. suggest you remove the large header tank before ‘you try to install the magneto box and engine mounts, Using firewall template, locate and drill 3/8" engine mount bolt hotes'and install Q2EHI-C stand-offs with AV3-1OA bolts. Install header tank. Install prop extension on engine prop flange, use anti-seize around ai1 lugs and bolt threads. Install engine on aircraft. A. Weight tail down and chock airfrane. BL Engine is to be off set slightly to the right to off set engine torque. bashers are supplied to be placed between ‘the EM1-C and’ the Continental #530741 washer on the left ‘engine mounts as needed (see plans for proper engine off set). Instat? propeller spinner flange. Install cow! A. Trim aft edge at firewall using spinner flange to locate forward end B. Space cowl 1 aft of the spinner flange CMake cowl mounting flange (see 0-2 construction plans 16-3). 1D. Rivet ‘cowl Flange to firewall E. Drill. smal positioning holes ‘to hold cowl in places celeos work well for this Instai] nutplates provided Remove cowl for Step. IiStep 1X Step x. Step x1. Step XII. Step KITT. Step XIIIV. ‘STEP CHART CONTINUED A. Position controls 1. Throttle 2) Mixtures 5) Carb heat = Alt, air. B. Install exhaust. C. Install carb. heat/att. air muffs. D. Instat? prefab Fiberglass air duct elbow to bottom of carb. E. Install neat transfer valve. F. Install_short section of 2.5" scat hose to Front of elbow & heat transfer valve. &. Install short section of scat hose connecting front. (cold side) of heat valve to prefab air inlet duct. A. Kiring & instrunentations. sRiternator leads 1 2. "Pleads. 3: Starter cable & Solenoid aD Engine ground 51 11 temperature Tine or wire, 6: O11 pressure Tine or wire, 7. GT Tea 8. CHT lead: 9. Tach cable (if mechanical tach. 1s used). 0. Manifold pressure Tine (if used) 1." Mount gas-co-lator on Forward side of the Firewall. 2) Aun gas Tine to gas-co-lator. 3. fun primer lines if carburetor doesn't have primer circuit. Renove engine. A. Seal firewall openings around wire and contro} holes. B. Fire proof firewall. C. Bolt voltage regulator to the firewall. Install aileron balance assembly. Bolt engine to airframe for final installation. A. Shim for engine torque, 1° right and 1° down. Tighten engine mount balts to 180 to 190 In. Tbs. Install cotter pins. Insta] all engine controts and hook-ups. Check for proper rigging and make sure there is no interference. Install cooling and induction system. A. Cut cooling inlet in Tower cowl. Install cooling ramp, and radius inlet. Cut induction air inlet using prefab scoop as 2 guide. lihen position is correct, perform Final trim, flox, and clecoin place. After cure, fair edges and tape 1 ply Bid. n'a out allowing I in. overlap, E. Install exhaust. systen. Engine Fun. A. Install prop, check for track BL Check for off leaks. Cl Use Continental guide for break-in run.NULIZE El OLOftd TFS SLeeT OFC 701-Fe0- m ‘ ie =e € WLI COP Kens \ Creech ws FOINCWE SSUW NOPFUE INIMVAO TLIC PAGE1The header tank used in this conversion is smaller than the tank used for the standard Revmaster engine, The main size difference allows hore room Fron the forward Face of the tank to the Firewall. The construction and mounting ts basically the sae as the larger tank, page 17-2, Q-2 Plans.” Use the perspective drawing to help guide you with the plumbing. Note the Following 1. The fuel punp sounted on the aft tank face 2. The fuel return tobe stops 1" below the top of the tank. A fuel vent line is stuck into the center of the return tube about a half an inch and exits thru’ the bottom of the tank, where it 15 connec to a hase which runs to a tube on the aft of the canard shear web, bent forward into the 4. The fuel that exits the fuel pump From the main tank enters the header tank 1" From the top, So fuel will not back drain thru the pump when it 1s off You can make a fuel indicator by using sone white foam and sanding it into @ small ball Paint it red and dip it into epoxy and allow to cure. Place it in the fuel Tevel tube making sure it is small enough not to get Stuck The installation of the header tank will require: you to crawl into your aircraft and lay on your Sack to do the attaching. You will have lots of space to Work and laminate. Those of you who still wish to install the larger tank will not have it as easy PAGE 2 HEADER TA be 6% (HAL) F72NN 29LON = Fuel Return To shut-off valve (then engine) «Vent ine Fuel gauge Vine Facet fuel pump Input from main tankPAGHETO BOX ASSEMBLY & ENGINE MOUNTING The magneto box assenbly serves three 1, Isolate and protect the aft accessory 2. To extend the firewall around the aft of the engine for Fire, fune and roise protection 3. Ta add additional strength to the FirewatT The box itself is made of 1/8" aircraft plywood, gIued together with flox and resin End'covered with 1 B10 cloth on each side. Tn _addition to the box itself, two vertical stiffeners run across the inside face of the Firewall. Full size templates for 211 pieces are given in the. appendixes. The Pieces are to be cut gut and assembled on the Firewall template. Five minute epoxy mnixea with a Tittle micro cen be dabbed on the pieces in small areas to help hold the pieces in place while the Flox cures. By covering the tenplate with waxed paper you can avoid soiling the template. In aircraft Where the instrument panel and, or header tank have already been installed, you will have to install the vertical stiffners after the box ‘sin place on the firewall. Sand a radius on the outside comers of the plywood. Cover inside and outside with 1 810. The vertical siffeners 02-8 8, 9, 10, & 11, are to be laminated with 2'B10 tothe firewall ‘on each side later on. The next step is to cutzout the hole jn the firewall using the full size template, This can be done at the tine the firewal] 4s cut-out before it is installed in the airframe or after it has deen attached to the airframe. Again, try to save the tenplate, for you can use it to Tocate engine mounting holes after magneto box is installed and the 4 BID local beet-up is cured. If you have already installed a header tank for: the Revnaster and now wish to install the Continental, T have sone bad news. We recommend you renove the tank from the airfrane for the fot Towing reasons ‘Stanclerd Continental aor aa fs, ese ae ie BE 1. Removing the header tank makes the Installation the header tank a heck of @ lot easier 2. The recomended header tank size is reduced to allow for more room behind the firewaily move it's cg aft and reduce co shift 35 fuel 1s consumed. ‘The loss of fuel capacity is to be made- up in a slight increase in main tank size and, or an-aft auxiliary tank in the baggage Compartnent area. The smaller header tank 4s recomended but you may wish to re-install the'larger header tank after the magneto box and engine mounts are installed: the choice 1s yours. Mount the magneto box in the firewall with flox and 2 2810. Put 2° tape on each Side. Also, lay-up the 4 810 pads inside and outside of the Firewall in the engine mount areas. Next install the stiffeners Q2-8M 8, 9, 10, A 11 on the inside of the Firewall. "You'will have to trim the outboard ends’ of the stiffeners to fit the contour Of the inside of the fuselage. After all this is cured, drill the 3/8" holes in Firewall for the mount bolts, make the EM-2 spacers and install the Q2 ENIAC ‘tount standoffs. "We have found that’ install ing the 3/8" mount bolts with the bolt heads facing aft will allow for easy engine instal lation and removal, With the bolt head lacked down ‘one man can unwrench the engine, 31 hough two are needed to Tift it on and off. Now it 1s time to trail tit the engine to the airframe. Chalk the tires to secure the aircraft. Lay-aut a butt line extending forward 3' past the firewall. When you install the inner engine mount’ rubbers, install a thick washer (Q2-EM4) on each of the left mount stand-offs as a starting place. Now instal] engine and remaining mount systems'and tighten 0 180-190 in-lbs.” Install ropellor extension, using snti seize on Prop flange and bolts. Tarque to 200-220 in-Ibs. and safety wire bolts one to one. Five lel} ZL, EZ LLEZ LILLE CLL PAGESLevel aircraft to wl 15 and drop a plumb bob from the center of the end of the prop extension to the butt Tne on the ground. he bod should end up-2 to 3" to the right fof the butt Tine. Now place a Tevel on top Of the engine case to make sure it is level. Engine position can be controlled by different thickness washers between engine mounts and Standoffs.” The engine off-set is to allow For engine torque, and you can correct for a’slightly warped firewall by using washers to. obtain correct TeFt-right and horizontal engine alignment. Check clearances between mmagneto box and starter, magnetos, alternator, ete. You should try to'maintain at least 2" at the closest points. Renenber, the engine will rock slightly at idle ocal Fire wall beef-u; to BO. ibs. ke ", e, fo 80m lbs, Old pale 4° 4 atch sl cate whens as pease re hte 7 ‘Neate “tiene ENGINE MounT <____. — Boss spouts tetmator used with his installation fs the B'8-C speciale FIREWALL 12 ap alternator”. Avaslable trom: Bilt Sotnbridve 518 Sunnyside Court eweon, Kansas. 67114 bie-2nd-ee62 It js well proven, Tight and compact unit and'wilT put ot-enough Power for instruments, radios ete, we are working on alight wesohey. smal STeemnstor conversion of 35 amps, vévicn wt supply enough power” for S04nR mesial acetetieny cover ar ALTERNATOR wet ber ete. Although it ts not rec~ fomended, larger alternators can be used by fodifying the size and shape of the nagneta bax to suit. The DenaTty will be @ reduction in foot, room: PAGE 4@ 8° "AE TOOL I-22? NUISN IGT 12773008 "O8E-OOE TBHL~ ~~ Mg-2B SHSM YF77 200d —*} (YSU 9-096 NE (9) 709 Monn PAGES > a INO-OL-BNO SLI08 NUSWIYITSSII TIES AL IE GITTIM GS i | (| Sxc08tn 9-096.N0 fo) SLI08 VE/y9NE (9) 827 WNMAC SOUS ~ OM LINMEs doudDPUL* 30 § COUNTERSINK 120° FOR FLUSH, AVEX POPS ORILL *30 £ COUNTER SINK NOTE: DRAWING NOT TO SCALE 1 cyeck took TOW urs is about 5° up From top half split line and 1.3" from AFT edge and measures 4.3" wide x 4.5". You can configure yours however you Tike Construction Steps: 1. Make @ full size cardboard pattern of the of1-check door, placina it on the outside of the top cowl ina. Draw a fine line argund the pattern 2. Grey tape the inside for a release, then lay-uo $ or 5 ply Bid allowing at least Ito the perineter dinension and fet cure. 3. Remove inside Tip lay-up, arey tape, and dremel saw the fine Tine you established instep 1 4, Trim door top so formed aluminum hinge can be flushed in place, floxed (being areful-not to. get epory/Tiox in hinge Svea) and flush riveted in place using fvex (1608-0412) pop rivets. QF course you roughed the hinge and attach area for 9008 bond 5, Trim inside cured 1ip allowing .2 inside stoo and .5 to .75 outside trim for Flox 6. Sand both inside surfaces, flox and celco in place. Wipe off excess, Squeeze out, and. instal] Hartwell flush Taten with #1604-0412 Avex rivets. 7. Fill recasses with micra in finish mode: PAGESTHROTTLE LINKAGE DETAIL 606/-~(735/-7-6) OR Seer rd “ AN 3/0 -3 / £:34/4(FAP N/A) AN 970-3 AN 3-// woxTuRe Be sure your MA3 carburetor has 2 155 #409 mixture arm. Ne installed a greased 4 bolt, sereved a MS-21042-4 nut on upside down, drilled next to the lower nut with A yee Grit then tightened another NS nut to the mixture wire. A loop of O80 safety Gite thru the ANE bolt head is the attach point for 2 Tight, spring to return mixture THh incase of cable failure. Secure mixture cable outer housing to Q-200 TP plate above) or attach bott [FINAL ENGINE INSTALLATION: Engine can be installed after firewall work is completed. Make sure spacers (stack of washers) have not changed or cowl ing will not alien with spinner, Rectorque engine mount bolts to 180-190 in. Tbs. MS-21042-4. indsafety with cotter keys. Check that all engine controls are hooked *50HLE up. Espectally magneto ground leads. Install propel lar using prop washer; torque bolts 216 in. Ibs. and secure with .040 safety wire, WX ARM Prop bolts should be re-torqued after 3 hrs. engine tine, then 10, and again st 25 hrs. and no more than 50 hrs. interval there-after. ‘Trim Spinner to fit around propel lor, drill & cleco attach holes thru bulk heads and install § K1O00-3 (10/32") anchor nuts with 3/32 s.0. flush rivets or 3/32 flush pop rivets. ‘ANH - 4-74 For new or re-nanufactured engines, check the Continental Service Guide for run-in. Check for fuel & of! Teaks. Monitor oil and engine tenperature and limit static run-ups. PAGEWER-STRETCHED SCREEN DOOR SPRING SAFETY WIRE HOT AIR 70 CARB. Exhaust and Muff Installation: Examining your extaust, you'll notice tangs on the forward right side. These are attach points for your hardware store variety, over-stretched 3/B" diameter screen door spring. We stuck @ screw= ‘river through the wire Toop at each end, clamped one screwdriver in the vise and pulled the other, overstretching the spring to at least ad ft. length. Then, safetying one end with .040 safety wire, each wrap is snugged uniformly and end secured at the second attach point. Check heat muff (0-200 HH) For Tength and trin if necessary. Spread slightly at the split to install, being careful not to over- spread at the welds and align for SCAT hose connection to side position of heat transfer box. Install a°stainless worn clanp securely about one inch inboard fron each end Bolt exhaust in place using 5/16 x 26 #22022 brass nuts and star lock, #535333 washers, torque 180 to 220in.. Ibs. SCAT, CAT WOSE INSTALLATION £ OUD WORM CLAMP See (HFETIES OUTER ior STRING g if ip Wits) cor. Lagy HIRE Hine, ss BEND LAST dG” 90° OUT. PAGES“FEAT TRANSFER VALVE SUPPORTS HEAT TRANS. VALVE ACTUATING ARM SCREEN ATTACHED WITH 5 MIN. OR FLOX FLAT FOR COWL CLEARANCE ‘SAFETY WIRE WRAPS AROUND. BOTH CYLINDERS —RETARDS CHAFING BLAST TURE PAGESTUNERMAN NUTS. ‘U” TYDE (WAS 395-6) ENGINE BAFFLING The engine baffling cones pre-cut to size and Presbent to shape. The rubber treated asbestos, aterial is cut and riveted by the builder to seal areas around engine baffling and cowl ing. Supplenent. this area with information an page 16-6 of the Q-2 Construction Plans. A blast tube is installed to 001 megnetos and alternator As outlined in the Q-2 Plans, use silicone to sea) small holes and gaps in the baffling. AS of this tine we have not found a need for an ofl cooler, it mould be a sinple modification to add one. The location would be the back face of the left baffling for 2 remote cooler, or the installation of the standard Continental oi] cooler assy PN#8526108. TYPICAL BAFFLE INSTALLATION ASWALL RIV. SILICONE WIDE BEFORE FINAL ASSEMBLY With REDUCE WEAR BF2 cones BLAST aF6 “3 ora BFS ore. SEPERATOR {040 SAFETY WIRE 6F/ 4:200-CHB-16'2 Q200-0CBik2 OUTER CYL. BAFFLE INVER CYLINDER BAFFLES Check conformity of bent tabs to cylinders. when satisfied of fit, place smell dabs of high temp. silicone on inside erimeter and place. Thread a Tong Toop of 040 safety wire thru center holes. ‘Place upper large diameter piano wire center of clyinders. Twist with wire twisters "til taught PAGE 10The cowl ing is 2 little Tong, to allow COOLING ATR THLET: Layout trim Vines for sketch & cut-out. sand 60 grit, 3/4” around cut-out in preporation for 2 ply bid. 45° Lay-up front side. Install 1" styro.or urethane foam to Fora inside Tip with small dabs of S'min. epoxy allowing } foam to protrude inside trim line. Radius foam 4" & avey from opening about 20" or 30°. Glass 2 or 3 ply bid, Tet cure, knife trim, and finally, renave Foam form: for individual building differences. Texporarily fasten spinner bulkhead to the end of the propellor extension. By attaching little spacers to the aft edge of the spinner bulkhead (about, you can trim the cowl ing to the fuselage and haintain a -10" gap between the spinner and the 10 Cou! ing. The details Tor the cox! ing installation are found in Q-2 Plans, page 16-3. The locet ion and shape of the air fnlets are different for ‘the 0-200 and are given in these plans. Also, ‘the cowl flap has been eliminated. After the awl ing has been cut to size and the cowl ing Flanges have been attached to the Firewall and the attach holes have been drilled between the Upper and lower cowl ing halves. Renove cowl ing ‘to install all nut plates, install air inlet radiue and air inlet for the carburetor, cut Oil door etc. If you have celcos (temporary Sheet metal fastners), they make positioning the Cowl ing easter during fitting and triming. Also, duct tape will help hold cowl ing in place during Fitting. At this point, rerove engine (do not ose track of mount. spacers) and install firevall and seal alT firewall openings around wires. and cowl ing. “You may bolt the voltage regulator and gascolator on the firewall at this time. Run primer Tines from gascolator to primer, and priner to intake spider and fuel Tine from shut-off valve to gascolator to carburetor, PAGETon rg Z <—z__ B55 vawy Lr0-1n9 wr 301s HOw? YW-GNY (GZ ATddY SV UWI? Woe x |. — - DINYWO 94 LO LAD A 1 orwwer 09 se A Seaton Wey ye >yeuayy ———|-- = - ase temo —| 252 0-79 *bujoue leq vou seuno ype woAy suos0{\e : is STW SSW WORST PAGE 12@:200-CHB-1$¢ 2 LELT REARAND SIDE VIEW WHER CYLINDER BAFFLES: “ { t 4200-/C81\¢2. | \ , | 2@ | I i I { J | | QUICKIE AIRCRALT CONTINENTAL BAFFLE JAN. 27, 83 PN ia WIRE a : OR EQUIV,DWPLE FOR LUSH RIVETS ANAL 6A OT @ B06 3°76 FEAR CENTER BAF? oO Q200-BF-4@200-BF-2 QUICKIE ARORA CONTINENTAL BAFFLE TAN 26, 83 oN Mab b Add ~ BEND 262. eave FABRICATE AND _| WSTALL AS DER LEST REAR BALELE ST ROT @ WIA 4 NNER CYLINDER BATTLESry AI SIE AND REAR VIEW | . ” RI ERONT TT a 4200-8F6 | a A / ‘OMPLE FOR FLUSH ANETS @-200-BF-3