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POSTING RULES

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11-05-2013, 10:17 AM
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Join Date: Jul 2012
Location: Hot Springs SD
Posts: 90
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The heat muff and exhaust pipe underneath it, are something that needs to be inspected every condition inspection. This does not require taking off the through rods and end plates, just take of the hose clamps and slide the shroud off, or open it up enough to take it off. This is very easy to do.
On another related note, the heat muff end plates need to be tight! if they can wiggle around, they will wear a groove in the pipe and if left long enough, can wear a hole through the pipe. We have had to replace a number of pipes over the years because of this.
Clint Busenitz /Vetterman Exhaust
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11-05-2013, 11:20 AM
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Forum Peruser
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Join Date: Jan 2005
Location: Austinville, Alabama
Posts: 2,458
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Quote:
Originally Posted by Mike S
Am I the only one who's (slightly warped) brain throws the suffix "weld" onto the thread title???
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No, Mike, you're not the only one. My brain also wants to read it as "...an engine overhaul with JB WELD"
But hey! It's the other Mike's thread, so he can title it anything he wants to, as far as I'm concerned. I'm just enjoying reading about it, and I'm glad he's posting his engine overhaul, so we can see what's involved. It's definitely a learning experience. 
__________________
Don Hull
RV-7 Wings
KDCU Pryor Field
Pilots'n Paws Pilot
N79599/ADS-B In and Out...and I like it!
?Certainly, travel is more than the seeing of sights;
it is a change that goes on, deep and permanent, in the ideas of living." Miriam Beard
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11-05-2013, 11:22 AM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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Ignition wires
As I pulled off the ignition wires, I gave them an inspection. They looked ok. A little grease and grime on a few. I own a workhorse, not a beauty queen. I could see one coil to ignition wire connection that showed corrosion and evidence of some arching, hidden by the boot of course. No evidence of any issues on this cylinder.
My top wires have been on since day one. Bottom wires have less. My bottom plug wire lengths are custom lengths. This due to mounting the coils on the engine mount and having each wire, well different lengths.
A call to Klaus revealed that his maintenance schedule, now published in a more current doc version online that I had from years ago, says replace these wires at 500hrs or 10 years. I had not ever considered this before. Hmmm. Well he is a pretty smart guy, so I ordered a new set. My average cost on these is $19.25 each. For 12 plugs this stung a little.
Plugs, I ve been going on the cheap for these using the BR8ES plugs at ~$2 each from day one. These have preformed well and last about 200 hours before they are worn and need replacement. I guess 'performed well' is an unknown. Engine runs, plugs fire and are reliable... I have no idea as to performance. Klaus recommended a fancier plug, a IK27 iridium plug that is a... wait for it... $15 each.  Im going to give them a try. Ill have no way of determining any performance difference other than plug life which Ill be able to measure. They will need to last 1500 hours to break even. Thats probably not a reasonable request of any plug.
Why wires need replacement? Im sure there is some electrical reason. I have cars with the original plug wires that are 15 years old and 150k miles. I of course have no way to measure any kind of deterioration of these. My mind says that a plug that fires is a plug and wire that are working. I'm sure its more complicated than that. A wires ability to carry this power surely degrades over time. An appreciable amount? I dunno. I don't race. I dont measure my performance to a nat hair. from Klaus "If you cruise at less than full throttle, you might not notice any wire degradation for a long time. At WOT you should see a performance increase when you change wires, even after 300 hrs." Like I said, Klaus is a pretty smart guy and has been doing this for a long time. So a new set of fancy plugs and wires it is. Seems unethical to install age old plug wires onto a new motor. My thinks my motor might protest.
Note: Picture. The plugs come in the proper packaging. I pulled them out to gap them and prepare for installing into the motor.
__________________
Kahuna
6A, S8 ,
Gold Hill, NC25
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11-05-2013, 11:29 AM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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Quote:
Originally Posted by rv7boy
No, Mike, you're not the only one. My brain also wants to read it as "...an engine overhaul with JB WELD"
But hey! It's the other Mike's thread, so he can title it anything he wants to, as far as I'm concerned. I'm just enjoying reading about it, and I'm glad he's posting his engine overhaul, so we can see what's involved. It's definitely a learning experience. 
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Oh. Im sorry about that. I saw Mikes note about welding and I thought it had something to do with welding my exhaust. NOW I get what he was saying. And since I HATE it when people title a thread to sensationalize to get people to pay attention to an otherwise boring piece, Ill change that now. I assure you I did not want anyone thinking that I was trying to play with thread titles to get people to pay attention. Its not my style.
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Kahuna
6A, S8 ,
Gold Hill, NC25
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11-05-2013, 11:33 AM
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Senior Curmudgeon
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Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 15,420
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Quote:
Originally Posted by Kahuna
I HATE it when people title a thread to sensationalize to get people to pay attention to an otherwise boring piece, Ill change that now. I assure you I did not want anyone thinking that I was trying to play with thread titles to get people to pay attention. Its not my style.
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Mike, my comment was actually directed at myself-------nothing wrong with the thread title at all. I just see some things a bit off kilter 
__________________
Mike Starkey
VAF 909
Rv-10, N210LM.
Flying as of 12/4/2010
Phase 1 done, 2/4/2011 
Sold after 240+ wonderful hours of flight.
"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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11-05-2013, 11:57 AM
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Join Date: May 2007
Location: Winder Ga
Posts: 914
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Quote:
Originally Posted by Kahuna
As I pulled off the ignition wires, I gave them an inspection. They looked ok. A little grease and grime on a few. I own a workhorse, not a beauty queen. I could see one coil to ignition wire connection that showed corrosion and evidence of some arching, hidden by the boot of course. No evidence of any issues on this cylinder.
My top wires have been on since day one. Bottom wires have less. My bottom plug wire lengths are custom lengths. This due to mounting the coils on the engine mount and having each wire, well different lengths.
A call to Klaus revealed that his maintenance schedule, now published in a more current doc version online that I had from years ago, says replace these wires at 500hrs or 10 years. I had not ever considered this before. Hmmm. Well he is a pretty smart guy, so I ordered a new set. My average cost on these is $19.25 each. For 12 plugs this stung a little.
Plugs, I ve been going on the cheap for these using the BR8ES plugs at ~$2 each from day one. These have preformed well and last about 200 hours before they are worn and need replacement. I guess 'performed well' is an unknown. Engine runs, plugs fire and are reliable... I have no idea as to performance. Klaus recommended a fancier plug, a IK27 iridium plug that is a... wait for it... $15 each.  Im going to give them a try. Ill have no way of determining any performance difference other than plug life which Ill be able to measure. They will need to last 1500 hours to break even. Thats probably not a reasonable request of any plug.
Why wires need replacement? Im sure there is some electrical reason. I have cars with the original plug wires that are 15 years old and 150k miles. I of course have no way to measure any kind of deterioration of these. My mind says that a plug that fires is a plug and wire that are working. I'm sure its more complicated than that. A wires ability to carry this power surely degrades over time. An appreciable amount? I dunno. I don't race. I dont measure my performance to a nat hair. from Klaus "If you cruise at less than full throttle, you might not notice any wire degradation for a long time. At WOT you should see a performance increase when you change wires, even after 300 hrs." Like I said, Klaus is a pretty smart guy and has been doing this for a long time. So a new set of fancy plugs and wires it is. Seems unethical to install age old plug wires onto a new motor. My thinks my motor might protest.
Note: Picture. The plugs come in the proper packaging. I pulled them out to gap them and prepare for installing into the motor.
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Somewhere in the recesses of this old brain, an instructor in Radar Fundamentals in the US Navy explained: any conductor or insulator exposed to high voltage, especially in harsh environments break down and lose their ability to conduct/insulate as when brandy new. Ask me how I know  So Klaus probably had the same info somewhere along the line.
__________________
Jerry Fischer KW4F
VAF# 1646
USS Randolph CVS-15 V-6 Div. AT2
RV7 N364SJ Miss Sandy sold 
RV1 N1583 "Mockingbird 1" SOLD
EAA volunteer SNF
HBC volunteer/co-chairman OSH
Tech counselor
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11-05-2013, 01:38 PM
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Forum Peruser
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Join Date: Jan 2005
Location: Austinville, Alabama
Posts: 2,458
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Quote:
Originally Posted by Kahuna
Oh. Im sorry about that. I saw Mikes note about welding and I thought it had something to do with welding my exhaust. NOW I get what he was saying. And since I HATE it when people title a thread to sensationalize to get people to pay attention to an otherwise boring piece, Ill change that now. I assure you I did not want anyone thinking that I was trying to play with thread titles to get people to pay attention. Its not my style.
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Aw, Mike, now I'm kinda sorry I mentioned it. I didn't think you were trying to sensationalize your thread. And by the way, I don't think anything you've ever posted here is boring. You are one of the most "un-boring" guys I've ever met. Keep the action going! 
__________________
Don Hull
RV-7 Wings
KDCU Pryor Field
Pilots'n Paws Pilot
N79599/ADS-B In and Out...and I like it!
?Certainly, travel is more than the seeing of sights;
it is a change that goes on, deep and permanent, in the ideas of living." Miriam Beard
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12-11-2013, 07:52 AM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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One expensive item found was damage to the rods. JB believes that the original engine builder did not use the correct socket when installing and put scratches in the face of the rods where the bolts seat. Magnaflux shows stress risers. This puts all rods into the junk category. Argh!  A very expensive problem fixed with new rods. You cant see much in the pictures, but here they are.

__________________
Kahuna
6A, S8 ,
Gold Hill, NC25
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12-11-2013, 08:11 AM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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Crankshaft
__________________
Kahuna
6A, S8 ,
Gold Hill, NC25
Last edited by Kahuna : 12-11-2013 at 08:26 AM.
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12-11-2013, 08:32 AM
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Join Date: Jun 2006
Location: 8I3
Posts: 3,564
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Kahuna the way you check plug wire condition is to hook an ohmmeter up to them then stretch and twist the wire and see if the resistance changes.
__________________
Please don't PM me! Email only!
Bob Japundza CFI A&PIA
N9187P PA-24-260B Comanche, flying
N678X F1 Rocket, under const.
N244BJ RV-6 "victim of SNF tornado" 1200+ hrs, rebuilding
N8155F C150 flying
N7925P PA-24-250 Comanche, restoring
Not a thing I own is stock.
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