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Thread: Changing out a 912 80 HP in a model IV

  1. #1
    Senior Member Wheels's Avatar
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    Default Changing out a 912 80 HP in a model IV

    Im replacing my original 912 80HP with a new one.
    Its going into my Model IV and so far the removal of the original engine has gone smoothly. The new engine is unpacked on the bench,
    1. I switched the intake and carbs so that it will fit into the Model IV round cowl engine mount.
    2. The CDI is in the way of the oil tank.
    3. The spider is interfering with the tank.
    4. The tank is too tall for the model IV so I had it shortened, the screen is still to tall and the oil intake tube inside the lid of the tank is too long. I'm really enjoying this, said no one ...ever.
    I can't wait to start the Dynon EMS D10 install. So, anyone else done this? Pointers, Spoiler alerts ... anything, ... anyone?

  2. #2
    Super Moderator Av8r3400's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    Why do you need to modify the oil tank? I've had two of these planes and both used the stock tank...

    I modified the firewall side of the engine mount with a tab to accept the ignition systems. Link
    Av8r3400
    Kitfox Model IV
    The Mangy Fox
    912UL 105hp Zipper
    YouTube Videos

  3. #3
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    Default Re: Changing out a 912 80 HP in a model IV

    I shortened my oil tank also, as did a guy in California. The firewall was made per the plans. I only removed the round portion on the bottom, so there were no changes to the pickup tube or the screen.
    Attached Images Attached Images

  4. #4
    Senior Member Wheels's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    The original tank was shorter by a couple inches to accommodate the round cowl. otherwise the oil door on the top won't close. The tank ends up crushing the electrical braid on the back of the engine. The new tube in the lid is going to have to be shortened as well, it goes the full length of the oil tank as does the screen.
    I like the placement of your modules. Did you have to lengthen the plug wires or did you use what you had? I"ll check on it today and start the fabrication process. I am going to have some help here for a week so I think I can get er done when my buddy arrives. He's an airplane guy from Alaska and pretty much works for food when he's on my place.

    I"ll send some pics as well.

  5. #5
    Senior Member Dusty's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    Are the early and late oil tanks a different length,also shifting the modules away from heat and vibration to the cabin side of the firewall can only be a good thing.

  6. #6
    Senior Member kmach's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    Why not use your old oil tank ?
    Kevin,

    Kitfox Outback
    912 ULS
    Airmaster AP332CTFH-WWR70W
    Summit Aircraft Wheel Skis
    C-FOXW

  7. #7
    Senior Member Wheels's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    The old tanks and new tanks are all the same hight. The Model IV round cowl had the tank shortened due to the tight space of the cowl. It reduces the oil quantity a minuscule amount.
    I want to use the new tank because it has an upgraded hose connection to A/N fittings and I like the fact that the inlet and outlet ports are on the lid. It makes identifying a crack or failure easy and and easier fix than pulling the tank.
    It looks like I will need to get longer plug wires and sheaths to move the CDI but I agree, moving it is the only option for lifespan of the part. Here is a picture of the tank and you can see that I need to shorten the rest of the hardware associated with the tank.
    Attached Images Attached Images

  8. #8
    Senior Member Slyfox's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    when I changed out my engine, I sent the tank to John and he fixed it up to the right height for me. I also updated to the new motor mount and new muffler. once I had everything put together on the new motor mount and mounts I went to the airport and swapped out engines in about an hour. easy very easy.
    steve
    slyfox
    model IV 1200-flying
    912uls
    IVO medium in-flight
    RV7A-flying
    IO-360
    constant speed prop

  9. #9
    Senior Member Wheels's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    I finished the tank tonight. It took about an hour to trim the extra length from the intake tube and trim the screen. Then I cleaned everything to make sure there was no metal shavings or screen material where it shouldn't be. I'll re organize the spider tomorrow for a good position on top of the engine for the tank.

  10. #10
    Guy Buchanan's Avatar
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    Default Re: Changing out a 912 80 HP in a model IV

    2. I moved my CDI to the upper right motor mount. (See photos.)
    3. I moved the expansion tank forward by rotating the head water outlets, replacing one of the expansion tank outlets with an elbow by brazing on a Rotax water pump elbow, and replacing all the tubing.
    4. I did the normal tank mods.

    In addition, you may find the new starter runs into your firewall. I machined off the lugs on the back of the starter and made a recess in my firewall. (See photo.)
    Attached Images Attached Images
    Guy Buchanan
    San Diego, CA
    Deceased K-IV 1200 / 912uls / 70" Warp 3cs

    gebuchanan@cox.net

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