Engine install completion - lots of little stuff

Working on finishing the engine install, and planning on running it when complete.

First item is the starter.  Having a dual battery system with 2 master relays means I have to pull off the 'bridge' between the two relays for the starter (so I can start on either or both batteries).  Been debating for awhile how to accomplish this.  Finally decided on a 4 position terminal adel clamped to the engine mount close to the relays.

Next is the air / oil separator.  There is no 'good' location... but finally just did it and will adjust later if necessary.  Per the UL manual, you want an uphill slope from the engine breather to the separator, and a downhill slope from the separator to the return.  I think I have this figured.

Back to an old problem... there was an issue with the oil return line from the air/oil separator that goes back to the sump.  I think it was bent, and got a replacement.  But I never finished installing it for some reason.  Need to get this fixed before putting oil in.  I did not put the screw back in that secures it.  I think that was because the oil line for the turbo needs to come off to do so... so that will be a job.

EGT's and CHT's are all installed.  Vacuumed out the exhaust by removing the waste gate to get any chips out so they do not get into the turbo.  I didnt hear anything when doing this...  

I checked the EFIS to see what the sensors were reading, and they were all not reading anywhere near correct.  Asked Advanced, and there was a bug with UL engines and direct read from the EMS.  New software obtained that fixes it (AF5000VX161036B06-MV16.afz).  Installed today, and works like a charm.  All probes are reading 'ambient-ish'.

Plug wires... I have been dreading this.  Like really dreading.  Making them looks right, not be a dogs breakfast all over the place, and was super worried about the electrical connections, etc.

So far, initial impressions are UL has this figured out.  One end is crimped, and the other end (engine side) has like a screw terminal inside the plug wire housing.  You literally just thread it in.

I labeled everything... which ignition it is coming from, and what plug ig goes to.  On both ends.  Yes, this is overkill...  Forward plug is ignition 1, aft plug is ignition 2.  Finished one side (3 cylinders, both plugs) in an afternoon.

Another builder and I had toyed with using the cross bar of the intercooler to organize the plug wires with some 3D printed parts.  I decided to go cheap and fast and just use HD plastic.  Used the grommet from the engine kit that goes in the aft end of the baffle as a template.  Small piece of angle aluminum and an adel clamp, and its done.

Exhaust pipes back from the ceramic coating.

Need to secure the bottom of the exhaust.  Brackets on the exhaust already installed.  Used the RV 'trick' of a thick hose as the support brace, with some stainless tabs on the end.  Need to get the correct hardware.

Fit the cowl, spinner and prop.  Lines up pretty good.  Not quite perfect, but close.

I started torquing the prop... but then found out (thanks Paul) about Service Bulletins from Airmaster.  One applies to me... brushes on the pitch change motor.  Email sent to Airmaster... my serial number is on the list.  Need to determine if the whole things comes apart again or not.

Brake lines from the park brake out are complete.

Turned the engine over from the starter with 6 plugs out.  Turned over great!  But... no oil pressure reading.  Talked to Ray... I turned it over for about 20 seconds.  Needs more than that.  Adding to the to do list.

The engine ground wire location is beneath the starter on the right hand side of the engine.  Long wire, pain to fasten.  Found an M8 threaded hole on the left side of the engine... shorter run, easier to install.  Seems to work great.

All lines are secure.

Shortened and rerouted the engine ECU to throttle body line.

Last thing is to obtain more hose for the breather and install.

'Almost ready to fly' my ass.  This has been a lot of work, and a lot of custom work.  Between the cowl, bracketry, exhaust, electrical system changes, this beast has taken a very long time.

Now onto the rest...