Mailing List flyrotary@lancaironline.net Message #2797
From: Ed Anderson <eanderson@carolina.rr.com>
Subject: Downsize inlet duct First Flight
Date: Wed, 3 Sep 2003 20:18:54 -0400
To: flyrotary <flyrotary@lancaironline.net>
The modification (reduction) of my radiator inlet duct area from a total of
48 square inches to 33 square inches is dedicated to Rusty (for obivious
reasons {:>))  Sorry, just couldn't help myself, Rusty,  - the devil made me
do it.

Ok folks, made the first flight today with my reduced/reshaped radiator
inlet for the left evaporator core.  The right evaporator core was left
unmodified to  provide a safety net sufficient to do the pattern and land
if
take off temps exceeded expectations.  Fortunately, that was not
necessary.
OAT on first take off was a humid 85 degrees.  No temperature increased
noted during ground run up, so launched and made max rate of climb, not
seeing any abnormal temp increase I left the pattern and continue Max rate
climb to 4500 MSL.  Max temp of coolant during climb was 210F (normal for
max rate climb at these OAT temps is 205F), Max oil temp was 200F nominal
for max power climb. Max temps were reached about 2/3 of the way through
the
climb.

In level flight, my coolant temperatures normally run 5 degrees colder
than
my oil temp.  Today my coolant and oil temps were the same.  So average
coolant temp was increased by 5 Degrees F.  Total radiator inlet duct area
was decreased from 48 square inches to 33 square inches.  24 Square inches
for the right inlet duct and 9 square inch inlet for the modified right
duct (See attached photo for comparision). Probably some drag benefit, but
did not try to investigate that
aspect.

I flew to an airfield 50 miles away to have my transponder recertified and
when I launched out of it, the OAT (ground level) was 92F

After level off I ran at different power settings to see the effect.

 5800 rpm burning 11.9  GPH at 4500  MSL with OAT at 78F My oil and
coolant
were both 190F.

5400 rpm burning 9.6 GPH at 4500 MSL with OAT 80F My Oil and coolant were
both 185F

5200 (Around my normal cruise rpm)  burning 7.25 GPH at 4500 MSL with OAT
80F My
oil and coolant were both  180F

In summary, the 33 % reduction in total  radiator inlet area appeared to
have increased coolant temps by an average of 5 Deg above the normal (the
old duct).  It could be that both the remaining radiator and perhaps the
oil
cooler are rejecting any additonal load with no problem.

It appears that smoothing out the path for the air from inlet to radiator
surface has benefited the cooling situation.  It could be that additional
heat may be rejected by the right (second in series) radiator as the
coolant
it received from the left radiator was probably now a bit hotter. I also
observed that the plate of the PSRU covers an area 3 " in from top to
bottom
of the rear of each radiator and the plate is only 2" from the rear of the
fins at its closest, so that is obviously not helping flow, the Ross Bell
housing did not, so a bell housing might improve flow conditions .

 I strongly suspect I would probably  find that a similar  reduction of
the
right radiator inlet duct to 9 square inches  would see my coolant (and
probably oil) temps increase considerable more than another 5 F.

OAT at  ground level was 94F when I landed, so not the hottest of days, but
not the
type I normally prefer to fly in.

>From what I have seen so far, I think it worth pursuing a reduction with
the
right radiator duct.  I will probably not reduce it as much for the reason
mentioned above. With some other things to take care of, probably won't
get
to it until later part of Sept at the earliest.  But, I have no problem
flying with current asymmetrical ducts, so will leave it as is for the
time
being and collect some more data.

It it appears that some cooling benefit is derived from providing a
smoother
transition from duct to radiator (even if far from a perfect
implementation
of the K&M approach) than my old duct provided.  The volume of the duct
was reduced by at least 60%, so while hard to tell from photos the white
"filler" material actually fills most of the duct.

Oh, yes, as an aside, its been 25 hours since I replaced the spark plugs
and
right on schedule - on the way back, I got the first SAG (Sparkplug
Attention Getter)  indication.  So it appears 25 hours on 100LL about the
average time for replacing plugs in my case.  I finally got a spark plug
cleaner, so need to clean a set (as the electrods do not appear worn) and
see if getting the lead off the ceramic  cone helps any.

Best Regards

Ed Anderson

Ed Anderson
RV-6A N494BW Rotary Powered
Matthews, NC
eanderson@carolina.rr.com
Subscribe (FEED) Subscribe (DIGEST) Subscribe (INDEX) Unsubscribe Mail to Listmaster