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LYCOMING FWF PACKAGES
AND ENGINES FROM ZENAIR
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O-360 FIREWALL FORWARD PACKAGE:
Zenair offers a complete FWF Package for the Lycoming 0-360-A4M aircraft engine for the Classic and the Heavy-Duty (HD) STOL CH 801 as well as for the Zodiac CH 640. These three 4-seat aircraft models perform very well with the 180 HP Lycoming and since they all use the same firewall, they use the same FWF packages (except for the engine-mount).
Zenair also offers a complete O-360 FWF Package for the new three-seat Super-Duty STOL CH 750-SD. Because engine space is a little tighter in the STOL CH 750-SD, additional FWF components are necessary for some of the engine accessories to fit (i.e. Remote Oil Filter, etc.). For installation instructions for the Lycoming engine, please also refer to the IO-370 instructions at Zenair's password-protected FWF Installation Website (access limited to Zenair/Zenith builders).
Zenair also offers a complete O-360 FWF Package for the new three-seat Super-Duty STOL CH 750-SD. Because engine space is a little tighter in the STOL CH 750-SD, additional FWF components are necessary for some of the engine accessories to fit (i.e. Remote Oil Filter, etc.). For installation instructions for the Lycoming engine, please also refer to the IO-370 instructions at Zenair's password-protected FWF Installation Website (access limited to Zenair/Zenith builders).
Elements provided in this FWF package include:
P/N O-360-FWF/750-SD ........for the CH 750-SD.........................$9,490.00 US P/N O-360-FWF/801 ..............for the CH 801/801-HD..................$8,765.00 US*
* The 180 HP Lycoming O-360 is not a recommended engine for the Super-Duty STOL CH 801-SD. See below for a suitable alternative.
- Engine mount (also available separately - see list below for price)
- Exhaust System (without heat shroud for cabin/carb heat) (also available separately - see list below for price)
- Propeller (Section K) - No longer included in FWF Package.
- Engine Cowl (fiberglass, two-part) (wider cowling available for the IO-360 series engines)
- Engine baffle kit (air cooling baffles not cut) (also available separately - see list below for price)
- Carburetor Air Box Kit (with carb heat) (also available separately - see list below for price)
- Oil Cooler Radiator Kit (includes cooler)
- Fuel Lines and back-up electric fuel pump Kit (pump for CH 640 only)
- Control Cables Kit (throttle, carb, mixture...)
- and much more...
P/N O-360-FWF/750-SD ........for the CH 750-SD.........................$9,490.00 US P/N O-360-FWF/801 ..............for the CH 801/801-HD..................$8,765.00 US*
* The 180 HP Lycoming O-360 is not a recommended engine for the Super-Duty STOL CH 801-SD. See below for a suitable alternative.
IO-390 FIREWALL FORWARD PACKAGE:
With the advent of the Super-Duty STOL CH 801-SD, Zenair is now also offering a FWF Package for the 215 HP Lycoming IO-390. This package is almost identical to the Zenair IO-375 FWF Package. Contact Zenair for details.
With the advent of the Super-Duty STOL CH 801-SD, Zenair is now also offering a FWF Package for the 215 HP Lycoming IO-390. This package is almost identical to the Zenair IO-375 FWF Package. Contact Zenair for details.
O-235 & O-233 FIREWALL FORWARD PACKAGES:
Zenair does not offer a complete O-235 or O-233 FWF package for the CH 601/650 or CH 750/Cruzer aircraft models at this time. We do, however, offer engine mounts, engine cowlings, an airbox kit and baffle kit. We can also provide an Exhaust system. See below for more information; call for details on the exhaust system and engine cowl.
Zenair does not offer a complete O-235 or O-233 FWF package for the CH 601/650 or CH 750/Cruzer aircraft models at this time. We do, however, offer engine mounts, engine cowlings, an airbox kit and baffle kit. We can also provide an Exhaust system. See below for more information; call for details on the exhaust system and engine cowl.
A NOTE ABOUT PROPELLERS:
Most customers looking for an inexpensive fixed-pitch propeller will find good second-hand props that are well-adapted for the Lycoming engine. For builders wanting a NEW prop, you will achieve better performances with a ground-adjustable propeller which can be fine-tuned for specific flight characteristics. See here for available props from WhirlWind.
Most customers looking for an inexpensive fixed-pitch propeller will find good second-hand props that are well-adapted for the Lycoming engine. For builders wanting a NEW prop, you will achieve better performances with a ground-adjustable propeller which can be fine-tuned for specific flight characteristics. See here for available props from WhirlWind.
LYCOMING ENGINE MOUNTS: (Mounts only)
Zenair can supply the engine mount only to builders installing a Lycoming (or a Lycoming "clone") engine on their Zenair design... "Engine mounts" do not include rubber mounts, brackets or hardware of any kind. Just the one-piece welded mount. These welded assemblies are oiled to minimize rusting - builders can primer, paint, powder-coat, etc. as they wish prior to installing for desired effect and corrosion-protection.
Zenair can supply the engine mount only to builders installing a Lycoming (or a Lycoming "clone") engine on their Zenair design... "Engine mounts" do not include rubber mounts, brackets or hardware of any kind. Just the one-piece welded mount. These welded assemblies are oiled to minimize rusting - builders can primer, paint, powder-coat, etc. as they wish prior to installing for desired effect and corrosion-protection.
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601/0235-D..........Dynafocal mount for CH 601/CH 650 (Lycoming O-235)...................................$790.00*/21
601/0235..............Conical (flat) mount for CH 601/CH 650 (Lycoming O-235)...............................$690.00*/21 750/0235-D..........Dynafocal mount for STOL or CRUZER CH 750 (Lycoming O-235)..................$885.00*/21 750/0235..............Conical (flat) mount for STOL or CRUZER CH 750 (Lycoming O-235)..............$785.00*/21 750-SD/0360-D....Dynafocal mount for Super-Duty CH 750 (Lycoming O-360)...........................$1,225.00*/21 750-SD/0360........Conical (flat) for Super-Duty CH 750 (Lycoming O-360)..................................$1,135.00*/21 801/0360-D..........Dynafocal mount for STOL CH 801-HD (Lycoming O-360)..............................$1,265.00*/21 801/0360..............Conical (flat) mount for STOL CH 801-HD (Lycoming O-360)..........................$1,175.00*/21 640/0360-D..........Dynafocal mount for CH 640 (Lycoming O-360)...............................................$1,215.00*/21 *These engine mounts are also compatible with engines from Aero Sport Power (see here) & Titan... |
LYCOMING CARBURETOR AIRBOX KITS:
Zenair offers these complete Airbox kits for the Lycoming O-235 and O-360 engines as installed in the corresponding aircraft models. Kits include all the parts to make the box and related hardware.
Zenair offers these complete Airbox kits for the Lycoming O-235 and O-360 engines as installed in the corresponding aircraft models. Kits include all the parts to make the box and related hardware.
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Lycoming O-235 Airbox kit
P/N: 0235-65/75-ABK For the CH 750 or CH 660 Assembly required.................................................$395.00 |
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LYCOMING ENGINE BAFFLE KITS:
These Baffle Kits are quite different from each other:
1) The baffles in the O-235 kit (P/N: 650/750-O235-BK) are completely finished and ready to slip over the engine and the kit includes the cabin-heat air-scoop and hardware;
2) The formed baffles in the O-360 kit (Section F) (P/N: 801-O360-BK/F) are similar to the O-235 baffle kit (ready to install), but accessories and hardware are sold separately (in Section G of the FWF Packing List)...
3) The baffles in the O-360 "Raw Materials" kit (P/N: 801-O360-BK/R) are drawn on the aluminum sheets but still need to be cut-out, trimmed and bent to fit - best for specialty installations...
These Baffle Kits are quite different from each other:
1) The baffles in the O-235 kit (P/N: 650/750-O235-BK) are completely finished and ready to slip over the engine and the kit includes the cabin-heat air-scoop and hardware;
2) The formed baffles in the O-360 kit (Section F) (P/N: 801-O360-BK/F) are similar to the O-235 baffle kit (ready to install), but accessories and hardware are sold separately (in Section G of the FWF Packing List)...
3) The baffles in the O-360 "Raw Materials" kit (P/N: 801-O360-BK/R) are drawn on the aluminum sheets but still need to be cut-out, trimmed and bent to fit - best for specialty installations...
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Lycoming O-235 Baffle Kit for CH 650/750 P/N: 650/750-O235-BK Pre-cut & formed (Exp) .....................................$634.00 (as illustrated) |
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Lycoming O-360/IO-375 Baffle Kits (Section F of FWF Pkg.)
P/N: 801-O360-BK/F or: Formed Baffles Kit (pre-cut and pre-bent)......................$585.00 P/N: 801-O360-BK/R Traced Baffles - uncut & without bends (Raw Material).......$351.00 Lycoming O-360 Baffle Accessories Kit (Section G of the FWF Pkg.) P/N: O-360-BA/G..... Baffle Accessories Kit ....................$85.00 |
Similar to formed O-235 baffles illustrated above. 
See Packing List for Contents |
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LYCOMING EXHAUST SYSTEM KITS:
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This high-quality stainless steel exhaust kit for your Lycoming is ready-to-install and available from Zenair for use on O-235-powered Zenair designs. Parts supplied include:
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LYCOMING CABIN HEAT KIT (includes carb heat components):
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This Cabin Heat Kit is included in the full Zenair O-360 FWF Package (Sec. 4) and it comes with an effective Windshield Defroster. The kit also incorporates all carburetor heat accessories for regular engine operations (NOT for fuel-injected engines). This kit can be purchased separately for custom installations.
Includes all items from Section 4 of the O-360 FWF Packing List. P/N: 801-CHO/360...........................................................$865.00 |
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Fiberglass & Plastic Parts from ZENAIR
Engine cowls and related accessories (spark-plug bubble-fairings, NACA scoop boxes, radiator intake boxes, oil-cooler intake ducts, etc. are traditionally made of fiberglass on most Zenair designs. These parts are generally included in Zenair's various FWF Packages as needed (see packing lists above), but can also be ordered separately. For a full listing of all fiberglass parts (and other vacuum-molded plastic airframe components) currently available from Zenair, see here: FIBERGLASS & PLASTIC PARTS
Engine cowls and related accessories (spark-plug bubble-fairings, NACA scoop boxes, radiator intake boxes, oil-cooler intake ducts, etc. are traditionally made of fiberglass on most Zenair designs. These parts are generally included in Zenair's various FWF Packages as needed (see packing lists above), but can also be ordered separately. For a full listing of all fiberglass parts (and other vacuum-molded plastic airframe components) currently available from Zenair, see here: FIBERGLASS & PLASTIC PARTS
LYCOMING ENGINES:
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Builders typically choose one of the following engines when installing a Lycoming on their Zenair kitplane.
The following are Non-certified (Experimental) engines. Model Model Specifications YO-233-X........... w. 12V SkyTec starter; No Ignition System* YO-233-X........... w. 12V SkyTec starter & Champion Ignt. Syst. YIO-233-X.......... w. Longer Oil Level Gauge; No Ignition* YIO-233-X.......... w. Longer Oil Level Gauge; with Ignition YO-360-A4M...... w. 12V SkyTec Starter; excl. Alternator YIO-360-M1A..... w. 12V SkyTec Starter; excl. Alternator The following engine model is the Certified O-235: O-235-N2C.....(replacement needed for certified aircraft) Engines are available directly from Lycoming, but can also be ordered from Zenair. Delivery: Approximately 90 days after receipt of order. Terms: Full payment due at time of order. Please contact Zenair by e-mail for current engine pricing *Can be factory-configured for Lightspeed Engineering ignition system. |
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Zenair and Zenith Builders: Remember that you have exclusive access to Zenair's on-line resources which include instructions, drawings and photo-assembly guides to help with the installation of your aircraft engine. To request your password, please complete the process outlined HERE. FWF resources are available HERE.
*All prices in U.S. funds. All prices, equipment, packing lists and availability subject to change without prior notice.
Prices do not include crating or shipping charges (Ex-Works, Midland, ON, CANADA).
Getting the installation information for Zenair-provided FWF Packages:
Once you have purchased your FWF Package, you will want the instructions on how to install it. Much of this information is found in the password-protected "Builder Section" of the Zenith Aircraft Website. In addition, many more valuable drawings and photo-guides are also available through the fairly new "Documents & Manuals" area of this (Zenair) site. Don't attempt your engine installation without access to these resources! To get the passwords, simply follow the instructions here.
A note about "deletions" from Zenair's FWF Packages:
Please note that the above FWF packages have been conceived, produced, sold, and crated to optimize efficiency as well as the value of each package. Individual component deletions result in reduced efficiency and increased costs; credits allowed for deleted components will therefore be adjusted to reflect this. Bottom line: Customers will receive less than retail credit for deleted components (including propeller). Thank you for your understanding.
Prices do not include crating or shipping charges (Ex-Works, Midland, ON, CANADA).
Getting the installation information for Zenair-provided FWF Packages:
Once you have purchased your FWF Package, you will want the instructions on how to install it. Much of this information is found in the password-protected "Builder Section" of the Zenith Aircraft Website. In addition, many more valuable drawings and photo-guides are also available through the fairly new "Documents & Manuals" area of this (Zenair) site. Don't attempt your engine installation without access to these resources! To get the passwords, simply follow the instructions here.
A note about "deletions" from Zenair's FWF Packages:
Please note that the above FWF packages have been conceived, produced, sold, and crated to optimize efficiency as well as the value of each package. Individual component deletions result in reduced efficiency and increased costs; credits allowed for deleted components will therefore be adjusted to reflect this. Bottom line: Customers will receive less than retail credit for deleted components (including propeller). Thank you for your understanding.