8
Weld on Injector Bosses
Your kit might include either steel or aluminum base injector bosses which must be welded onto your
induction tubes on some Lycoming, Continental or Jabiru engines. In the case of weld on types, the
injectors should be mounted as near as possible to the intake ports, pointed towards the valve. Be sure
when determining placement, that you can run fuel lines and fitting to the boss tops which won’t be too
close to exhaust pipes or any other obstructions. Be sure you’ll be able to get the TIG torch all the way
around the boss to do a good weld. Also be sure to check that you’ll have cowling clearance for the boss
and fuel fittings feeding it.
Weld-in injector boss Make oval hole in induction tube
Mark the outside of the tube where the boss will be
placed. Find the center of your mark and center punch
it. Drill a 1/8 inch hole through the tube. Enlarge to 7/16
with a step drill. Take a 7/16 drill bit and put it straight
through the hole. Lean the drill down slowly so an oval
hole is cut into the tube to match your injector boss (45
degree angle). Line up the boss carefully with your hole
(a cut off 7/16 bolt through the boss base, clamped in
place, can help align it while tacking). Carefully tack the
bosses in place, recheck fit and clearance. Remove the
bolt before final welding. Final weld in place once you
are satisfied everything is right. Injector boss welded in place ( Lycoming)
Throttle Body Mounting
80, 60, 45 and 40mm throttle bodies
Lycoming Vertical Induction Engines
We supply a 60mm throttle body for these engines to fit in place of the carb or RSA-5 Bendix servo on O-
320- O-540 engines. The TPS and throttle arm are already mounted. Use an ACS 2.5 inch aluminum
flange and supplied 2.5 inch silicone hose coupler to connect to air filters or the SDS FAB kit mount for
Van’s aircraft.
O-235 and O-290 engines use the 45mm throttle body.
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