GLOBAL VIEW CARACTERISTICS ASSEMBLY INSTRUCTIONS
GLOBAL VIEW CESSNA 150
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GLOBAL VIEW CARACTERISTICS ASSEMBLY INSTRUCTIONS
CARACTERISTICS CESSNA 150

1-Output Improvement

This exhaust was designed in order to increase the engine output:

Photo Primary pipe, 4 branch manifold

Every cylinder outlet tube - primary tube - is 880 mm long. This is the optimal length considering the data from the manufacturer (length, bore, valve opening, etc.), and the available space inside the engine compartment.

Each pipe has the same volumic length, and neutral fiber. Identical lengths of primary pipes ensures an equivalent output for each cylinder, reduces fuel consumption, diminishes engine vibrations by approx. 60%, which leads to a higher level of comfort.

The 4 branch manifold – 4 primary pipes linked to a collector and to an outlet – enables a good mix of the gases, increases available torque and power.

Cylinder head flanges are made from 316 L stainless steel. Primary pipes and collectors are made from inconel 625 sheets. With a high thermal resistance, this alloy insures an excellent reliability to the exhaust.


Photo Cylinder head flange.

 

2-Silencer

The silencer works along two principles :


A chamber made out of a drilled sheet of metal ensures the diffraction.

Padding around the relaxation chamber, made from layers of insulating material, enable the absorption.

The acoustic gain, of approx. 15%, due mainly to the loss of high frequencies, significantly improves the acoustics’ onboard.

3-Silencer mounting

The available space inside the engine compartment is not sufficient to receive the silencer: it is fastened under the cockpit.

The cylinder head flanges insure the rigidity of the collector’s fastening on the engine.

The engine mounted on silent blocks has a certain mobility compared to the cockpit, during cruising for instance.

All the conditions put together imply a specific stud, and the right build between the collector and the silencer.

Photo Screw and fastening bolt of the silencer Vertical tie rods Silencer clamp.



A twin ball joint pipe between the outlet pipe and the silencer compensate vertical and lateral movements.

During manufacturing great care is taken for the sealing of the twin ball joint, without reducing the mobility


Small vertical tie rods link the silencer clamps with the cockpit. They compensate lengthwise movements of the silencer.

Structural elements which support the silencers are made out of 15CDV6T, which is used in aeronautics for mechanic-welded components. Surface treatment prevents them from corroding.

Paulstra type supple ball joints enable a vibration free link up between the tie rods and the under cockpit supports.This combination of mechanical elements enables mobility between the collector and the silencer, limits mechanical constraints, and improves global reliability.

 

 

 

 

GLOBAL VIEW CARACTERISTICS ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS CESSNA 150

1 – Remove upper and lower engine cowling.

2 – Dismantle original gas recuperation box.

3 – Keep the four cylinder head gaskets.

4 – Detach the original cabin heating and carburetor heating boas.

5 – Remove pilot and copilot seats, as well as the carpet covering the access hatch under the seats.

6 – Dismantle the air box support, behind the air exit depression pump,

7 – Pull out the rubber tubing out of the depression pump, on the pump side.

8 – Detach the aluminium air/oil exit pipe. Replace with the new bended pipe D16 (7 ). Attach both extremities with serflex collars.

9 – Pull out RHS cold air intake, fixed onto the aluminium plate, by drilling holes into the 4 aluminium rivets.

10 – Unscrew the 4 air box screws. - Assemble the air box support (5 ) with original M10 bolt onto the upper part, and the 2 M5 screws and M5 Nylstop nuts (44) on the inferior part.

11 – Cut the original cabin heating boa d75mm to the length L=290 mm

12 – Pre assemble the carburettor heating assembly (1) on the front left primary pipe ( 101) index it on the support welded on the primary pipe.
12 – Fit the 11 M4 flat headed screws (21) and auto lock washers D4 (22) . Tighten all the screws.

11 – Pre assemble the cabin heating assembly (2) onto the 4 branch exit pipe (42). Make sure the air intake d50 is orientated towards the 4 branch manifold. 11 - Fit the 18 M4 flat headed screws (21) and auto lock washers D4 (22), w/o tightening.

12 – Install the D16 aluminium breather (7).
12 - Attach both extremities with serflex collars

13 – Assemble the 4 primary pipes (101 to 104) w/o forgetting the exhaust washers. Slightly screw the 8 nuts (106) w/o tightening.

14 – Fit the 4 branch manifold ( 41 ) into the primary pipes, match the numbers engraved on the primary pipe flanges (105) with those on the 4 branch manifold.
14 – Attch the H M5 L= 12 mm screws (43) and the M5 Simmonds nuts (44).15 – Strongly tighten the bolts (44).

15 – Block the 8 nuts (106) of the primary pipes.

16 – Install the serflex collars (13) on the carburettor heating boas (11) , cabin heating intake boa (12) and cabin heating exit boa. Do not tighten.

17 – Fit one extremity of the carburettor heater boa ( 11) on the hot air intake pipe of the carburettor box and he other on the outlet pipe of the carburettor heating assembly (1) placed on the primary pipe. Check the boa is well in place and tighten the d50 serflex.

18 – Orientate the exit fitting on the depression pump in order to have sufficient clearance between the rubber tubing and the front left primary pipe.
18 – Attach the rubber tube against the intake pipe with a plastic clamp in order to keep it away from the primary pipe.

19 – Drill the 6 fixing holes D5 mm of the fresh air intake bend (8 ) and fresh air exit bend (9) along the guideline REF : Notcessna02-0120 – Fit the fresh air intake bend (8) on the upper part of the aluminium sheet, around the d50 hole, with the opening towards the front of the aircraft.

20 - Fit the fresh air outlet bend (9) on the underneath of the aluminium sheet, around the d50 hole, orientate the opening towards the cabin heating assembly intake (2)
20 – Attach the 6 M5 screws (81) and M5 Nylstop nuts (82). Tighten.

21 – Fit one extremity of the the D50 mm cabin heating boa (12) into the end of the fresh air outlet bend
20 - (9) then the other extremity on the cabin heating assembly intake (2).
20 – Check the boa (12) is properly in place and tighten the Serflex collars (13).

22 – Fit one extremity of the D70 cabin heating boa onto the hot air outlet of the cabin heating assembly (2) , and the other extremity onto tje hot air intake on the firewall.

23 – Orientate the cabin heating assembly (2) in order to have the boa’s extremities in line with the hot air outlet bend (9) on one hand and the hot air intake on the firewall on the other hand.

24 – Tighen the D50 Cerflex collars (13) and the D70 collars at both extremity of the cabin heating boa.
20 – Tighten the 18 M4 flat headed screws (21) and D4 auto lock screws (22) of the cabin heating assembly (2)
20 – Fasten a Cerflex collar against the lower extremity of the cabin heating assembly to keep it in the right position on the 4 branch manifold outlet.

25 - Check that all the fuel pipes or electrical cables are far away from the exhaust manifold. If not isolate with thermal protection every part that might be deteriorated or divert with a clamp.

26 – Remove the 4 rivets under the cockpit, by drilling with a D4 mm bit, then with a flattened burin according to the installation plan REF:CESSNA150-05
24 – Drill the 4 D6 silencer support holes following the plan REF: CESSNA150-05
25 – In case the inter-axis difference between the under cockpit holes (31) and the rivets is too high, replace under cockpit rivets with Ø4 recess head rivet.

23 - important : - Drill one of the original rivets for the first support hole
23 - important : -Drill Ø6 second hole using the support (31) as benchmark.

27 – Install the front silencer support, according to the orientation on the plan plan REF : CESSNA150-05
25 – Attch both M6 L=30mm ChC screws and M6 Nylstop nuts. Tighten.

28 – Install the rear silencer support, according to the orientation on the plan plan REF : CESSNA150-05
26 – Attch both M6 L=30mm ChC screws and M6 Nylstop nuts. Tighten.

29 – Fit the silencer (15) in the support clamp (33) w/o tightening in order to leave some movement for fitting.

30 – Apply high temperature copper grease inside the fittings.

31 – Fit the extremity of the simple ball joint pipe (6) , female side on the 4 branch manifold exit pipe (42)
28 - Fit the other extremity of the simple bal joint pipe (6) , male side into the silencer (15) by sliding
28 – the silencer (15) lengthwise towards the front, in order to have a perfect fit between the elements.

32 – Twist the simple ball joint pipe (6) so that the ball joint is as much as possible in line with the longitudinal axis.
29 – Tighten the Chc M6 screws and Simmonds M6 nuts on each fitting.

33 – Tighten the 8 Chc L=35mm screws and Simmonds M6 nuts of the 2 silencer clamps.

34 – Check each element is properly in place and sufficiently tightened.
31 – Check there are no tools, screws, nuts or other misc. left inside the engine compartment.

35 – Install upper engine cowling
32 - Install lower engine cowling

36 – Tighten engine cowling screws.

Voir schéma Implantation rondelle air froid
Voir Schéma Implantation des supports silencieux sous cockpit
Voir Schéma position du silencieux sous cockpit