Modifications to Chinook + 2 Rotax 582 cooling system
You can see here that the ignition coils for the CDI system are mounted to the frame of the aircraft under the black cover. This is to isolate vibration and heat, but mostly to make it easier to work on. Ignition wires are standard automotive resistance suppression wire. My radio is noiseless. Trailer plugs are used on all wiring, so the engine can be removed easily. A tank drain is also under the cover.The radiator is also mounted to the frame brace of the aircraft, and is very narrow. The radiator is the heater core from a bus, and is made of brass. It has 5 rows of tubes, and has more cooling ability than is needed..
A "1 inch" spacer is used on the prop flange to allow a 66 inch prop and clearance for the radiator. The engine is equipped with a thermostat and a small hole was drilled in it to allow for filling. A 70 % coolant mix is used to raise the boiling point.
Now for the radical part: The entire system is unpressurized and is filled through the little plastic bottle seen above the gearbox. This also serves as expansion tank and sight level. There is no pressure cap. The hose to the cap is a vent line to the small screw port on the waterpump housing. This line allows venting for filling or gasses in the system. I never need to add coolant as the expansion tank is alway cool and condenses all vapour.The reason for this system is to prevent any possibility of a "blown hose" or leak, and to remove pressure from the waterpump lip seal.

An emergency warning "OVERTEMP" switch is screwed into the front cylinder head and will light a red lamp on both of the panels if temperature gets to 190 degrees. ( It has never lit.) Temperature seems to run at 140 degrees and is rock steady no matter what I do. I have flown at 6000 MSL with no problem.

A lift handle was placed on the body tube, but this modification is of marginal value. It is too heavy to lift at that point, so I just use it to push it around at fly-ins.
The strobe is mounted to the top of the rudder, as I am most worried about traffic behind me. The strobe box is also mounted under the black cover.
I want to mention again, that the craft now has 300 hours on it, and all these modifications work extremely well.
INDEX Page #12 Rotax carburetor sockets made to last. ( lLINK)
Page #10
Hosted by www.Geocities.ws

1