Ted's RV-10 Construction Blog: More airbox stuff

More airbox stuff

The completed airbox mounted on the injection servo. Note the depression on the side. On my first effort, this depression was too far to the rear and the mixture arm was hitting it at about half through it's stroke.. I had to completely dissassemble the airbox (drill out about 40 rivits) and reglass the cutout. Then I got to do the installation all over again.
Another view of the airbox. Notice the offset from the center at the servo mount. If you mount the airbox using the supplied top plate (the one that bolts to the servo) it does not appear to be possible to offset the airbox enough to clear the mixture arm. I had to make another top plate with the inlet hole offset from the center in order to get clearance. It's done, and it looks good ! But it took a LOT longer than it should.
Once the airbox is done, then you get to build a tunnel from the scoop inlet to the airbox inlet. This is done by putting a foam block between the two inlets and carving a hole through the center. Then you lay up some epoxy resin and cloth and hold the whole mess in place with a balloon. NOTE: Don't inflate the balloon with your air hose cause you will almost certainly not like what happens. Much safer to get close and personal with the balloon and put your lips on it.
If you do it right, you will have roughly the same amount of balloon sticking out of both ends. The aluminum piece is to hold the bottom of the mold in place cause it blew out the first time I inflated the balloon.

# posted by Ted : 4:22 PM

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