X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from QMTA03.emeryville.ca.mail.comcast.net ([76.96.30.32] verified) by logan.com (CommuniGate Pro SMTP 5.2.12) with ESMTP id 3483734 for flyrotary@lancaironline.net; Mon, 09 Feb 2009 07:35:02 -0500 Received-SPF: pass receiver=logan.com; client-ip=76.96.30.32; envelope-from=wschertz@comcast.net Received: from OMTA12.emeryville.ca.mail.comcast.net ([76.96.30.44]) by QMTA03.emeryville.ca.mail.comcast.net with comcast id DoU41b00N0x6nqcA3oaR8Y; Mon, 09 Feb 2009 12:34:25 +0000 Received: from WschertzPC ([71.57.77.95]) by OMTA12.emeryville.ca.mail.comcast.net with comcast id DoaF1b00223NHuF8YoaQSq; Mon, 09 Feb 2009 12:34:25 +0000 Message-ID: <654F4E717C234FBFBFC4E85954D38BCC@WschertzPC> From: "Bill Schertz" To: "Rotary motors in aircraft" References: In-Reply-To: Subject: Re: [FlyRotary] New failure mode Date: Mon, 9 Feb 2009 06:34:13 -0600 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0028_01C98A80.6C73B8A0" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Windows Mail 6.0.6001.18000 x-mimeole: Produced By Microsoft MimeOLE V6.0.6001.18049 This is a multi-part message in MIME format. ------=_NextPart_000_0028_01C98A80.6C73B8A0 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Thanks Lynn, sounds like a good safety. Bill Schertz KIS Cruiser #4045 N343BS ----- Original Message -----=20 From: Lynn Hanover=20 To: Rotary motors in aircraft=20 Sent: Sunday, February 08, 2009 10:07 PM Subject: [FlyRotary] New failure mode From: Bill Schertz=20 To: Rotary motors in aircraft=20 Sent: Sunday, February 08, 2009 5:30 PM Subject: [FlyRotary] NEW failure mode for 13B Well, I haven't heard of this happening before -- I was ground running = my engine to tune it with the EM-2 and EC-2. Ran for almost an hour, = at various rpm's to change the manifold pressure and tweak the settings. = Cooling working well, I had the top cowling off to allow good exit area = since I was tied down. Coolant pressure about 14 psi as reported on the = EM-2. Engine was running good, took it up to ~6000 rpm swinging a 76x76 = Catto prop, when suddenly there was steam and fluid on my windshield. = Shut it down by killing power to the EC-2. Coolant everywhere. Got out and looked to diagnose the problem -- NOT my plumbing. A = FREEZE PLUG in the iron housing had blown out. Rapid coolant dump. Secondary effect -- Since I shut down suddenly from full tilt, either = the proximity of the cowl to the exhaust, or possibly some of the = coolant on the exhaust started a small fire on my cowl. Put it out with = extinguisher, but corner is charred. Bill Schertz KIS Cruiser #4045 N343BS Now in repair mode. It is not a common thing to have happen in any engines. In Cosworth = blocks I did this mod just because the blocks cost as much as my house. = I have seen one fall out of a rotary, because pure water was left in = over a winter. It was a plug in the front iron and allowed water into = the pan. The bearings were lost and I got a rebuild job out of that one. = When replacing the plug with a new one, wire brush the anodize off of = the sealing sides of the new plug.=20 With a die grinder just break the outside corners of the hole. Apply = a thin coat of Non Hardening Permatex gasket cement to the hole walls and outside of the plug.=20 Cover the plug with a piece of aluminum. Drive the plug in with a = heavy, slow moving hammer, to just flush.=20 You might think about adding two or three 8-32 or 10-32 threaded screw = holes around the edge of the hole and install a small washer that covers = part of the plug as shown. Use socket head screws and wire as shown. = When you overhaul an engine replace all of the plugs with new.=20 Lynn E. Hanover -------------------------------------------------------------------------= ----- -- Homepage: http://www.flyrotary.com/ Archive and UnSub: = http://mail.lancaironline.net:81/lists/flyrotary/List.html ------=_NextPart_000_0028_01C98A80.6C73B8A0 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
Thanks Lynn, sounds like a good=20 safety.
Bill Schertz
KIS Cruiser #4045
N343BS
----- Original Message -----
From:=20 Lynn=20 Hanover
Sent: Sunday, February 08, 2009 = 10:07=20 PM
Subject: [FlyRotary] New = failure=20 mode

From:=20 Bill=20 Schertz
To: Rotary motors in = aircraft
Sent: Sunday, February 08, 2009 = 5:30=20 PM
Subject: [FlyRotary] NEW = failure mode for=20 13B

Well, I haven't heard of this = happening before --=20 I was ground running my engine to  tune it with the EM-2 and = EC-2. =20 Ran for almost an hour, at various rpm's to change the manifold = pressure and=20 tweak the settings. Cooling working well, I had the top cowling off to = allow=20 good exit area since I was tied down. Coolant pressure about 14 psi as = reported on the EM-2.
 
Engine was running good, took it up = to ~6000 rpm=20 swinging a 76x76 Catto prop, when suddenly there was steam and fluid = on my=20 windshield. Shut it down by killing power to the EC-2. Coolant=20 everywhere.
 
Got out and looked to diagnose the = problem -- NOT=20 my plumbing.  A FREEZE PLUG in the iron housing had blown out. = Rapid=20 coolant dump.
 
Secondary effect -- Since I shut down = suddenly=20 from full tilt, either the proximity of the cowl to the exhaust, or = possibly=20 some of the coolant on the exhaust started a small fire on my cowl. = Put it out=20 with extinguisher, but corner is charred.
 
 
Bill Schertz
KIS Cruiser=20 #4045
N343BS
Now in repair mode.
 
It is not a common thing to have happen in any engines. In = Cosworth=20 blocks I did this mod just because the blocks cost as much as my = house. I have=20 seen one fall out of a rotary, because pure water was left in over a = winter.=20 It was a plug in the front iron and allowed water into the pan. The = bearings=20 were lost and I got a rebuild job out of that one.
 
When replacing the plug with a new one, wire brush the anodize = off of the=20 sealing sides of the new plug.
 
With a die grinder just break the outside  corners of the = hole.=20 Apply a thin coat of Non Hardening Permatex
gasket cement to the hole walls and outside of the plug.
 
Cover the plug with a piece of aluminum. Drive the plug in with a = heavy,=20 slow moving hammer, to just flush.
 
You might think about adding two or three 8-32 or 10-32 threaded = screw=20 holes around the edge of the hole and install a small washer that = covers part=20 of the plug as shown. Use socket head screws and wire as shown. When = you=20 overhaul an engine replace all of the plugs with new.
 
Lynn E. Hanover
 

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Homepage:  http://www.flyrotary.com/
Archive and=20 UnSub:  =20 = http://mail.lancaironline.net:81/lists/flyrotary/List.html
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