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Rob's REBVAIR Project
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Date: 5-18-2014
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Number of Hours: 2.00
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Manual Reference:
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Brief Description: Coil/gascolator cooling box Part 1
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On WW's Wagabond (when first completed by one of his staff), an aluminum box was constructed to allow cooling air from the baffling to wash over the ignition coils and gascolator. The box is fairly well described on WW's website, so I knew the general size requirements. The tricky part is where to locate it on the Rebel. The key design considerations were 1) which side..left or right? I wanted the gascolator to be on the left, so the fuel line between it and the carb would be as short as possible, 2) ensuring the gascolator drain was easily accessible without removing the lower cowling panels, 3) ensuring the gascolator was not located directly above the engine exhaust pipe (fire), 4) not interfering with the placement of the air/oil separator which needs to stay on the left side, and high on the firewall, and 5) avoiding interference with any critical reinforcing structures on the Rebel firewall.
For the latter consideration, close observation of the firewall right under the coil-attach bracket reveals some witches hats and engine mount reinforcements that need to be taken into account.
To start,Image 1 shoes the heavy chunk of 2024 C-angle aluminum I purchased from online metals.com. Can't recall what paid for it, but I do recall that shipping was more than the part itself. I knew this might be overkill, but the coils are 1.5 pound each, and given the way they are mounted (a clever design plagiarized from WW's team), I wanted to have a really strong part that could withstand the significant bending loads imparted by the AN3 bolt/pressure block. As you can see, I did try to lighten the part somewhat.
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