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Firewall
Details
Initial firewall modifications required for the installation of a Continental IO-360 will be the installation of a fuel boost pump (red) and a voltage regulator for your new 60 amp alternator. I ran all the electrical wires through the firewall, tagged them and left excess for final trimming after the engine was installed.
I tried to use the existing holes in the firewall to plumb all lines. I found using this location for the major electrical wires, provided the best clearance from fuel lines and controls. I purchased an electronic voltage regulator with built-in over-voltage protection. The Tyee STC provides a cockpit over-voltage light and guarded switch to kill the charging circuit. When we tested the electrical system with the alternator and regulator on line, we encountered some bizarre indications and noises. The regulator continuously clicked and the over-voltage light flickered. I spent several days checking my wiring and discussing the problem with zefftronics without success. Finally, they told me to ship the regulator to them and they found it was faulty! I can't get a brake.
The starter relay, located in here, allows for a short wire to the starter.
Here you can see the fuel boost pump and dual resister for low boost adjustment (via throttle position switch). No fuel lines are provided in the Tyee conversion fwd of the firewall and contrary to the STC holder, you can not use your original fuel line to connect original gascolator to the boost pump. On my first attempt, seen here, straight fuel line fittings produced unacceptable bending in the fuel line. I purchased a second fuel line and set of 90 degree fittings, $300 worth, and found the fit perfect. For the price these types of items should be included in the Tyee STC installation kit.
The location of the engine mount tubes and engine-integral oil filter prevents utilizing the cabin-heater box in its original location on the pilots side of the firewall. Also note that in this photo the engine has yet to be converted from an IO-360-C to a D as indicated by the sideways mounting of the vacuum pump.
Things nearing completion, but still a C model engine.
Here's how we solved the cabin-heat box problem. The muffler inlet and outlet accept 3 inch scat. We used the original heat box and mounted a 3 inch adaptor to the heat inlet, barely visible in this shot. The box was then mounted to the firewall, and we ran 2 inch scat to the heat vents. Dave Miller
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