Express Aircraft Construction

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Wing Construction
Fuselage Construction
Empennage Part One
Empennage Part Two
Elevator
Rudder
Ailerons/Flaps
Instrument Panel
Firewall Forward
Bodywork/Paint

 

 

 

Firewall Forward Fabrication and Assembly

Engine uncrated and the engine mount has been attached.

 

Attaching the engine and mount to the firewall.  First test fit.

 

The nose gear strut and nose wheel have been attached to the engine mount.

 

To dress up the firewall, the aluminum surface is machine turned with two inch overlapping circles.

 

All firewall penetration holes have been located and drilled. 

Hard points have been bonded to the face of the firewall to attach various components.

Fire proof fiber frax is being attached.

The two lower square hard points support the engine mount and nose gear.

 

The aluminum firewall is attached. 

Also mounted are the battery box, fuel pump, master cylinder, and solenoids.

 

Proper air circulation for cooling is attained by fabricating aluminum baffles.

Here manila folders are used as templates which will be traced onto aluminum.

The starter ring gear and propeller have been attached at this point.

The lower half of the cowling has also been fit and attached.

 

Attaching and fitting the aluminum baffles. 

They are fabricated from .032 aluminum.

Fuel and oil lines (blue silicone) are in place.

The exhaust system has been installed.

All engine probes (EGT and CHT) have been installed.

 

Running the control cables (throttle, mixture, and propeller) through the firewall and into the instrument panel.

 

Silicone rubber baffling is attached to the aluminum baffles to make a seal against the upper cowling.