Water pump 4

 The stainless steel elbow is inserted 

at the base of pipe AA1 and joins to 

the lower elbow before connecting 

to the water radiator.

Water Pump 3

 

Connections to the Water pump and the radiator are using formed rubber pipe, some of which require trimming to size. The pipe from the cooling reservoir that sits on top of the engine has a 90 degree elbow and feeds down through the body of the engine to a stainless steel elbow. From here a preformed pipe hooks around the engine frame to the upper inlet of the water radiator.

Adjustable hose clips will secure the ends of the pipes to complete the cooling system

Main Undercarriage 2

 Axles are removed and the Wheel pant bracket is captured behind the 4 bolt heads on the inside of the undercarriage leg.

The main axles are secured by the 4 bolts. Chance now to pack the inner wheel bearings with grease before sliding the wheel onto the axle. In order to facilitate wheel removal the disc ring is easily removed from the wheel using a 5mm Allen key.

Main Undercarriage

 

The Bracket that supports the wheel pant is made of mild steel and has already started to rust. This deserved some TLC in the way of blasting and powder coating gloss white.

In order to remove the sharp edges of the holes in the brackets, a spherical drill stone was used. 

The finished result was a quality finish in preparation for the rebuild of the axles and wheel bearings.

Engine Lifting Bracket

At special request to a ship colleague on my most recent vessel, and in accordance with the Bristell Build Manual, a mild steel lifting bracket was made for the purpose of lifting the engine onto the bench, modifying the water pump and finally offering the engine and mounting frame up to the firewall.

Water Pump 2

 

             

                        

The middle hole is used to align the spout horizontal and to starboard. This outlet then connects to the bottom spout on the radiator.

Water Pump

 The water pump was stripped down before Xmas and the pipework reconfigured to fit around the engine frame. Now is the time to complete the rebuild before mounting the engine and frame on the firewall.
The Rotax Heavy Maintenance Manual describes the assembly of teh pump and requires the torque setting for the 4 mounting bolts at 10N/M. A soft liquid gasket by the name of Wellseal was used to coat the machined surfaces of the pump pace either side of the paper gasket. The bolts were inserted and torqued up sequentially. Loctite 242 was used on the threads as there are no lock washers used in the assembly.
The mounting bolts in the 6 o’clock position is shorter than the others and behind the bolt head is a copper washer. This bolt is actually a drain for the water system. To complete the rebuild, the outlet fitting is bolted onto the outer face of teh pump and a rubber o-ring is seated into a groove of both mating faces.

              

Gascolator & Bracket

The Gascolator bracket is specific to the Andair Style Gascolator and mounts on the starboard side of the firewall. This bracket was lightly blasted and powder coated in gloss white. When it came to mounting it using the usual 1/8th inch pop rivets i found that the nozzle of the gun would not sit square onto the bracket before squeezing, This resulted in a rivet head that wasn’t flush and it looked awful. As an alternative, i decided to use solid rivets which achieved a much better finish.