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Zenith CruZer & Sonex Logs
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Date: 10-3-2010
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Number of Hours: 3.50
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Manual Reference: n/a
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Brief Description: Engine Prep & Rework Battery Box
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Well, based on investigation yesterday, I thought I could invert the accessory plate that fits on the back of the engine in order to move the starter to the passenger side of the firewall. I checked the Tom Wilson book, and could see no difference in the engine case, but to be sure, I asked the Sonex discussion group.
Well, it turns out that Sonex cuts a starter clearance hole in the engine case. I dug out my engine parts just to double check, and sure enough, the hole is there. Sinex my canopy is now finished, I could remove the canopy shipping box from underneath my workbench, so I unpacked the engine parts and set them up in logical groups on that lower shelf. I also gathered all the parts related to pressing on the prop drive hub just in case I decide to tackle that some day soon.
So, given the starter access issue, plus remembering that the intake manifold ALSO runs in the area of the battery, I bit the bullet and refabricated the battery box to allow a slide-out side access for the battery. I left the box in the plane. First, I drilled and cleco'd two hinges to the outside corner of the box. I then took my saber saw and cut down that corner line. Took my time and was careful.
I then drilled-out the rivets on the outside edge inner corner against the firewall. This allowed the side panel to come free. I filed / deburred all edges and adjusted the foldover edge where the hinge clearance would be an issue. I made up a hinge with hole spacing to match the firewall holes, and riveted it all together. Results are as shown in the picture. Now I can really get started with the wiring!
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Converted Battery Box
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