Return-Path: Received: from [24.25.9.100] (HELO ms-smtp-01-eri0.southeast.rr.com) by logan.com (CommuniGate Pro SMTP 4.3c3) with ESMTP id 830995 for flyrotary@lancaironline.net; Wed, 30 Mar 2005 22:12:29 -0500 Received-SPF: pass receiver=logan.com; client-ip=24.25.9.100; envelope-from=eanderson@carolina.rr.com Received: from edward2 (cpe-024-074-185-127.carolina.rr.com [24.74.185.127]) by ms-smtp-01-eri0.southeast.rr.com (8.12.10/8.12.7) with SMTP id j2V3BgLw006673 for ; Wed, 30 Mar 2005 22:11:43 -0500 (EST) Message-ID: <000801c5359f$60634d80$2402a8c0@edward2> From: "Ed Anderson" To: "Rotary motors in aircraft" References: Subject: Re: [FlyRotary] Rev-4 wanders around the airport under it's own power Date: Wed, 30 Mar 2005 22:11:46 -0500 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0005_01C53575.76896A10" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook Express 6.00.2800.1106 X-MIMEOLE: Produced By Microsoft MimeOLE V6.00.2800.1106 X-Virus-Scanned: Symantec AntiVirus Scan Engine This is a multi-part message in MIME format. ------=_NextPart_000_0005_01C53575.76896A10 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable MessageGreat to hear you are back flying, Rusty. It will be really interesting to see what your prop does. I asked for = Clark to give me 100 RPM more out of the prop which should amount to 285 = rpm more on the engine side. That will give me close to 6000-6200 = static (depending on OAT). I liked the performance on those cooler = mornings getting 6000 rpm static - really made it roll down the runway = quickly. Err I presume you made it clear to Clark that those were engine = rpms and not prop rpm {:>) - if not you should be seeing around 7500 = static. Should get my prop tomorrow. I have induction system #6 waiting to = stick on the engine and see what it does. Then put the new Digital Fuel = Monitor in place and see how it does - works perfect in my shop and we = know what that is worth {:>). Sort of tough getting your BFR in your RV-3 isn't it? I need to = complete my conditional inspection before heading to Sun & Fun later = this month. Sure be nice if your test area extended that far, looks = like Bernie may try to make it in his rotary RV-9. Stay out of the Navy's hair and watch out for those hail stones - boy, = they could down an RV with no problem. Best Regards Ed A ----- Original Message -----=20 From: Russell Duffy=20 To: Rotary motors in aircraft=20 Sent: Wednesday, March 30, 2005 8:21 PM Subject: [FlyRotary] Rev-4 wanders around the airport under it's own = power Greetings, The Rev-4 rebuild is nearing first flight readiness. I just put the = prop back on yesterday, and took it for a spin around the airport today. = Despite some tuning touch-up that's needed (trying to hold off for a = test of the auto tune feature), the engine is running fine. =20 The only problem I've had on the last two starts was, well, the = starts. Last time I ran the engine, it took almost a full battery to = get it cranked. Today, for the first time EVER, I ran the battery down = without getting the engine started. Nothing is wrong, but I guess I = need to relearn my technique. In fairness to the Odyssey battery, the = stupid under drive pulley hasn't been letting the battery charge much in = the previous runs. I really hate having the EM-2 blinking at me anytime = I get below about 2000 rpm. I may have to reset the low limit. =20 I ran the engine up to 4800 rpm while attempting to hold the plane = with the brakes. It sure seems strong, and this isn't close to full = throttle. I had a 6000 rpm static before, and asked Clark to give me = 500 more rpm when he did the final finish on the prop. My static = should now be 6500+ Zoom, zoom :-) The engine has not leaked a drop of anything, and it stayed quite cool = today. I never saw oil over 130 degrees, or water over 170 during my = joyriding. The evap cores had their ducts in place, but the oil cooler = did not (since it's built into the lower cowl). Turning the engine = over by hand seems really tight. All the tolerances when building the = engine were at the very tightest limits, so this is going to take some = time to break in. =20 The cowl is functionally complete, which means all the parts are stuck = together, and can be bolted to the plane and flown. I still have tons = of cosmetic work. I haven't sanded any of the overlapping joints, where = I bonded the scoop, or new front ring. There are drips and runs of = epoxy everywhere. Just disgusting :-) The oil scoop is not rounded on = the front edge, which I know is not good, but I strongly suspect that = it's going to be way oversized, so anything I do to it now will just be = a waste of time. I'm actually hoping that it's too big, because I need = to do some cosmetic surgery to it. =20 I formed the lower cowl shape (to clear the oil cooler), and the oil = cooler duct separately, which was a mistake. I just guessed at the = shape of the scoop that would look OK with the lower cowl. = Unfortunately, it could use some work on the cosmetics. No point = messing with it until I get a clue about the necessary scoop inlet size. = The water was never a problem, but now I'm running Evan's NPG-R, so I = would expect temps to go up 20 degrees or so. On the other hand, the = cowl exit area has gone up about 50 sq inches, due to the lowering of = the rear edge of the cowl for oil cooler clearance, so I suspect I'll = make up everything I lost on the Evan's. The oil cooler is a complete = unknown. It's BIG, and should be very efficient. It's far more = vertical than the old one was, so the airflow through it is MUCH = improved. The inlet is currently 30 sq inches, and I'm optimistic that = it's going to be too much. I have some wacky plans to limit airflow = through the cowl exit when it's not needed, but I don't see that = happening until I need to (temps too low in cruise). =20 So what's needed- Nothing really. I suppose I could put it all = together, tune the engine (or not), and fly it tomorrow. That's not how = it's going to happen though :-) I plan to add the gear leg stiffeners = in the next few days, and I'm still hoping to come up with a new = expansion tank for the coolant that will house my new level sensors. = Still waiting for UPS to bring my supplies, and I need to do some = testing on the sensors. The plumbing of the new tank is driving me = crazy. I just haven't come up with a perfect solution yet, though I = think I know what I'll have to do. After tomorrow, I'm illegal, but I = have my medical and BFR scheduled for Monday. Hopefully, I'll be ready = to start seriously running the engine by then, and start doing laps over = the airport. I'm off next week, but of course the Navy is flying, so my = airport is limited to a 1400 ft ceiling unless I beg Pensacola to let me = climb through Whiting's area. =20 In a side note, Whiting won't be flying too many helicopters. We had = a huge hail storm Saturday, with up to 3" hail stones. One of my RV = buddies is a helo instructor at Whiting, and he was off yesterday = because they didn't have anything to fly. By his account, there are = about 100 grounded helicopters, almost all of them. He said all but a = few had broken windscreens, and most had damage to the main rotors. = Check out the bike riders helmet in the Pensacola News Journal online = article! = http://www.pensacolanewsjournal.com/news/html/D4524BC4-A982-4CF5-858C-474= 8672FA25B.shtml That's way more than enough for now. =20 Rusty (not long now) ------=_NextPart_000_0005_01C53575.76896A10 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Message
Great to hear you are back flying,=20 Rusty.
 
It will be really interesting to see = what your prop=20 does.  I asked for Clark to give me 100 RPM more out of the prop = which=20 should amount to 285 rpm more on the engine side.  That will give = me close=20 to 6000-6200 static (depending on OAT).  I liked the performance on = those=20 cooler mornings getting 6000 rpm static - really made it roll down the = runway=20 quickly. Err I presume you made it clear to Clark that those were engine = rpms=20 and not prop rpm {:>) - if not you should be seeing around 7500=20 static.
 
Should get my prop tomorrow.  I = have induction=20 system #6 waiting to stick on the engine and see what it does.  = Then put=20 the new Digital Fuel Monitor in place and see how it does - works = perfect in my=20 shop and we know what that is worth {:>).
 
Sort of tough getting your BFR in your = RV-3 isn't=20 it?  I need to complete my conditional inspection before heading to = Sun=20 & Fun later this month.  Sure be nice if your test area = extended that=20 far, looks like Bernie may try to make it in his rotary = RV-9.
 
Stay out of the Navy's hair and watch = out for those=20 hail stones - boy, they could down an RV with no problem.
 
Best Regards
 
Ed A
----- Original Message -----
From:=20 Russell=20 Duffy
Sent: Wednesday, March 30, 2005 = 8:21=20 PM
Subject: [FlyRotary] Rev-4 = wanders around=20 the airport under it's own power

Greetings,
 
The Rev-4 = rebuild is=20 nearing first flight readiness.  I just put the prop back on = yesterday,=20 and took it for a spin around the airport today.  Despite some=20 tuning touch-up that's needed (trying to hold off for a test of = the auto=20 tune feature), the engine is running fine. 
 
The only = problem I've had=20 on the last two starts was, well, the starts.  Last time I = ran the=20 engine, it took almost a full battery to get it cranked.  Today, = for=20 the first time EVER, I ran the battery down without getting the = engine=20 started.  Nothing is wrong, but I guess I need to relearn my = technique.  In fairness to the Odyssey battery,  the stupid = under=20 drive pulley hasn't been letting the battery charge much in the = previous=20 runs.  I really hate having the EM-2 blinking at me anytime I get = below=20 about 2000 rpm.  I may have to reset the low limit. =20
 
I ran the = engine up to=20 4800 rpm while attempting to hold the plane with the brakes.  It = sure=20 seems strong, and this isn't close to full throttle.  I had a = 6000 rpm=20 static before, and asked Clark to give me 500 more rpm when he = did the=20 final finish on the prop.   My static should now be=20 6500+   Zoom, zoom :-)
 
The engine = has not leaked=20 a drop of anything, and it stayed quite cool today.  I never saw = oil over=20 130 degrees, or water over 170 during my joyriding.  The evap = cores had=20 their ducts in place, but the oil cooler did not (since it's built = into the=20 lower cowl).   Turning the engine over by hand seems really=20 tight.  All the tolerances when building the engine were at the = very=20 tightest limits, so this is going to take some time to break in.  =
 
The cowl is = functionally=20 complete, which means all the parts are stuck together, and can be = bolted to=20 the plane and flown.  I still have tons of cosmetic work.  I = haven't=20 sanded any of the overlapping joints, where I bonded the scoop, or new = front=20 ring.  There are drips and runs of epoxy everywhere.  Just=20 disgusting :-)   The oil scoop is not rounded on the front = edge,=20 which I know is not good, but I strongly suspect that it's going = to be=20 way oversized, so anything I do to it now will just be a waste of = time. =20 I'm actually hoping that it's too big, because I need to do some = cosmetic=20 surgery to it. 
 
I formed the = lower cowl=20 shape (to clear the oil cooler), and the oil cooler duct separately, = which was=20 a mistake.  I just guessed at the shape of the scoop that would = look OK=20 with the lower cowl.  Unfortunately, it could use some work on = the=20 cosmetics.  No point messing with it until I get a clue about the = necessary scoop inlet size.   The water was never a problem, = but now=20 I'm running Evan's NPG-R, so I would expect temps to go up 20 degrees = or=20 so.  On the other hand, the cowl exit area has gone up about 50 = sq=20 inches, due to the lowering of the rear edge of the cowl for oil = cooler=20 clearance, so I suspect I'll make up everything I lost on the = Evan's. =20 The oil cooler is a complete unknown.  It's BIG, and should be = very=20 efficient.  It's far more vertical than the old one was, so the = airflow=20 through it is MUCH improved.  The inlet is currently 30 sq = inches,=20 and I'm optimistic that it's going to be too much.   I have = some=20 wacky plans to limit airflow through the cowl exit when it's not = needed, but I=20 don't see that happening until I need to (temps too low in=20 cruise).  
 
So what's = needed- Nothing=20 really.  I suppose I could put it all together, tune the engine = (or not),=20 and fly it tomorrow.  That's not how it's going to happen though=20 :-)  I plan to add the gear leg stiffeners in the next few days, = and I'm=20 still hoping to come up with a new expansion tank for the coolant that = will=20 house my new level sensors.  Still waiting for UPS to bring my = supplies,=20 and I need to do some testing on the sensors.  The plumbing of = the new=20 tank is driving me crazy.  I just haven't come up with a perfect = solution=20 yet, though I think I know what I'll have to do.  After tomorrow, = I'm=20 illegal, but I have my medical and BFR scheduled for Monday.  = Hopefully,=20 I'll be ready to start seriously running the engine by then, and start = doing=20 laps over the airport.  I'm off next week, but of course the Navy = is=20 flying, so my airport is limited to a 1400 ft ceiling unless I beg = Pensacola=20 to let me climb through Whiting's area. 
 
In a side = note, Whiting=20 won't be flying too many helicopters.  We had a huge hail storm = Saturday,=20 with up to 3" hail stones.  One of my RV buddies is a helo = instructor at=20 Whiting, and he was off yesterday because they didn't have anything to = fly.  By his account, there are about 100 grounded helicopters, = almost=20 all of them.  He said all but a few had broken windscreens, and = most had=20 damage to the main rotors.  Check out the bike riders helmet in = the=20 Pensacola News Journal online article!
 
http://www.pensacolanewsjournal.com/news/html/D4= 524BC4-A982-4CF5-858C-4748672FA25B.shtml
 
That's way = more than=20 enough for now. 
 
Rusty (not = long=20 now)
 
 
 
 
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