Mailing List flyrotary@lancaironline.net Message #2543
From: Russell Duffy <13brv3@bellsouth.net>
Subject: I'm legal, but need a new heat shield plan
Date: Sat, 16 Aug 2003 19:14:30 -0500
To: Flyrotary List <flyrotary@lancaironline.net>
Message
Greetings,
 
Well, I'm 3 for 3 with the local DAR, and now have an airworthiness certificate for the plane.  This is getting easier every time, and I didn't anticipate that it was going to be a problem.
 
As soon as he left, I started replacing my primary injectors.  Of course this meant pulling the turbo and intake out of the way enough to get the injectors out.  That was all pretty easy, since I didn't have to remove any hoses or anything to move the turbo and intake a couple inches.  The new injectors are in, and don't leak fuel under pressure.  Unfortunately, I couldn't run the engine due to the incredible thunderstorms.  Heck, I feel lucky to be alive with some of the lightning that was hitting all around my hanger :-)  
 
Now, here's the problem of the day.  I used that exhaust wrap stuff that everyone sells for wrapping headers, but I wrapped the turbo with it.  As I was removing the stuff to get to the nuts to remove the turbo, I found that it had cooked into a hardened form, and literally crumbled to (irritating, fiberglass-like) dust when trying to get it off.  It was OK on the pipe itself, but anywhere that touched the turbo was toast.  This sort of puts me back to square one with heat shielding.  I can probably go ahead and run the engine tomorrow, since the top cowl is off, and there's plenty of airflow, but I will certainly need to do something before closing up the cowl and flying.  
 
Option 1-  I can probably make a flat stainless shield that would go between the intake and turbo.  This would block the heat from the intake, but wouldn't protect anything else.  If I do this, I'll need some sort of heat coating for the inside of the cowl.      
 
Option 2- I still like the idea of wrapping the whole turbo with some sort of heat insulator, but need suggestions of what could be used.  Eventually, if the turbo is working out, I'd probably buy a new turbo and manifold, and have them ceramic coated.  The current turbo and manifold are Ebay items, that I got cheap.  The manifold has the standard cracks, and the turbo has a bit more play than I like in the shaft.  I never had any plans to run these for a long time, just long enough to prove the turbo is worth keeping.   
 
So, for all you folks that know more about heat shielding material than I do, what should I be looking at, and would you think this material would be suitable for wrapping the turbo itself?  
 
Thanks for any suggestions.
Rusty (legal, but stupid enough to fly yet) 
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