Paul could you please post the
drawing for the oil pan and
include the
materials and dimensions?

I'll be using a mount almost identical to the CH-801 you
previously
designed. Also same for the S-beam? When fabricating the
S-beam what radius
is desired for the bend please? Does one use a hole saw
for
the lightening
holes or a fly cutter? Thanks a bunch. I have an autocad
viewer, so should
be able to view a .dwg or .dxf file.

C. Smith

Here are some old designs but they may need to be adjusted
your type of airplane.


Paul Lamar


What is the material & thickness for the oil pan?I'm
assuming 6061-T6,
but not sure on thickness.

I did make note of 0.063" 4130 -- so will place that on the
next Aircraft
Spruce Order.

C. Smith -- as to hole saw or fly cutter:  I'd
recommend the hole saw, as
you are cutting through a weld bead on the 4130 box. I guess you could
clamp the two pieces side by side and cut the
holes before bending the 4130.Make sure Paul has
everything
designed for your 801 before you start cutting.  On
the photos is look like
the tubes are welded in place into the beam, so I suspect a
milling machine
with a fly cutter will come in handy to "surface to top" to
keep everything
equal when tightened down.

Tom

How good are you at welding aluminum. Some people can weld
beer can :)

Anything from .049 up to .1875 will work with some weight
trade off. I
suggest a little tig practice to see what you can do. Check
the oil pan bolt
pattern as the RX8 engine differs from the 13B. Use the
bolt center finders
and tap the aluminum down on top to center punch the holes.
A carbon fiber
oil pan will work with high temp epoxy and with the upper
center hard point
type mount found on the 801 and the BearHawk.

If it is a Zenair 801 I have an improved  mount for
that using the upper
center hard point. I'll redo the old dwgs.

Don't get me wrong. If you have a 801 mount this new one
will not be worth
retrofitting. The only way to get the airplane done is
freeze the design at
some point and build it. Both mounts will work.

Paul Lamar

I'm building a CH-640, not an 801. They do share the
firewall with the
exception of the upper center mount point. 640 is a low
wing, whereas the
801 is a high wing, and the upper point is there to help
transmit the loads
to the spar, as I've been told by Zenair. I only said that
it is very close
to the 801 mount. Don't need the upper point, so no need to
re-do.
I'll be using light weight center and end housings, so I'm
just starting
with the S-beam to use in a test stand/mock-up until all
the fuel injection,
MSCD ignition is finalized. Once a final installed weight
is determined,
then we would go ahead with finalizing mount design for the
640.
So the s-bean is fabricated in 2 C-channels? I don't see
the cross-section
dimensions, just the long  view. What is the bend
radius please?
I've done a bit of tig welding, will be purchasing my own
welder soon, but
have access to some nice equipment at work.
Thanks for the tips Jerry, Tom, Paul.
C. Smith

OK that will require a rear motor mount of a different
design.
Are the firewall angle back and hard point dimensions the
same as the
801? If not I will need a sketch and the the distance from
the firewall to the prop flanges as well as the position
of the thrust line.

The S-beam length is going to be a function of the cooling
system
chosen. Side rad or bottom rad? One must find out if
everything
is going to fit in the cowl :)

Paul Lamar



I'll get the numbers and drawings organized for you in as
soon as I can.
C. Smith

Firewall angle and hard points are identical, Zenith uses same lycoming mount, minus high point
attachment.
Bottom Rad will be used.

I will double check thrust line and FW to prop flange distance, IIRC
they are the same. One difference here is I will be using the RB LW end
and center irons. I recall you said this may be significant enough to
require moving the engine CG further out.

As I will also be P-port Lamar-EFI, Lamar MSCDI, there is no need for
the factory crank angle sensor, I will leave this out and plug opening.
Likely to be using Tracey Cook RD1-C gear drive
( http://www.rotaryaviation.com/RD-1C.htm ).
Variprod CS propellor system.
( http://www.variprop.com/company.html )

C. Smith