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12-11-2013, 09:14 AM
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Join Date: Jan 2005
Location: 57AZ - NW Tucson area
Posts: 10,011
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Quote:
Originally Posted by Kahuna
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.

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Is it possible that the rod nuts were installed backwards at first and then reversed?
http://www.lycoming.com/Portals/0/te...od%20Bolts.pdf
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Gil Alexander
EAA Technical Counselor, Airframe Mechanic
Half completed RV-10 QB purchased
RV-6A N61GX - finally flying
Grumman Tiger N12GA - flying
La Cholla Airpark (57AZ) Tucson AZ
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12-11-2013, 10:17 AM
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Join Date: Apr 2010
Location: Ridgeland, SC
Posts: 2,589
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Kahuna---
Have JB send you the rods! They would look cool on a plaque on the wall in your house!!!!!
Paper weights, Trophies, etc. Yep, unusual, but cool.
Tom 
__________________
Tom Swearengen, TS Flightlines LLC, AS Flightlines
Joint Venture with Aircraft Specialty
Teflon Hose Assemblies for Experimentals
Proud Vendor for RV1, Donator to VAF
RV7 Tail Kit Completed, Fuse started-Pay as I go Plan
Ridgeland, SC
www.tsflightlines.com, www.asflightlines.com
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12-11-2013, 12:17 PM
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Join Date: Jan 2005
Location: SC
Posts: 12,887
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Quote:
Originally Posted by TS Flightlines
Kahuna---
Have JB send you the rods! They would look cool on a plaque on the wall in your house!!!!!
Paper weights, Trophies, etc. Yep, unusual, but cool.
Tom 
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That or sell them to the airboat guys in FL to recoup some of your $$$.
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Bill R.
RV-9 (Yes, it's a dragon tail)
O-360 w/ dual P-mags
Build the plane you want, not the plane others want you to build!
SC86 - Easley, SC
www.repucci.com/bill/baf.html
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12-11-2013, 12:24 PM
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Join Date: Jan 2005
Location: SC
Posts: 12,887
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Quote:
Originally Posted by Kahuna
...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. ....
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Kahuna,
I run the BR8ES with my P-mags and using the EICommander to monitor them. What I have discovered is that around 100 +/- hours, the EICommnader starts to report some anomalies with these plugs. However, you would never know it by the feel of the engine, performance, or fuel burn. Since I replace my plugs ever condition inspection about 135 hours, I continue to use the cheap ones.
I also replace my plug wires every two years, if it needs it or not. When I was racing my Miata, I would replace them every year and I figure that car ran cooler than my ECi O-360. Like you, I have to make my plugs wires.
Check with Klaus but Emag mentions that you should have "approximately 180 ohms of resistance per foot of plug wire". That may be one way to test your wires.
In addition, I use dielectric grease on my plug wire fittings for no other reason than I figure "it can't hurt".
Keep up the posts, it is a great education!
__________________
Bill R.
RV-9 (Yes, it's a dragon tail)
O-360 w/ dual P-mags
Build the plane you want, not the plane others want you to build!
SC86 - Easley, SC
www.repucci.com/bill/baf.html
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12-11-2013, 02:03 PM
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Join Date: Apr 2010
Location: Ridgeland, SC
Posts: 2,589
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Yeah Bills idea is better.
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Tom Swearengen, TS Flightlines LLC, AS Flightlines
Joint Venture with Aircraft Specialty
Teflon Hose Assemblies for Experimentals
Proud Vendor for RV1, Donator to VAF
RV7 Tail Kit Completed, Fuse started-Pay as I go Plan
Ridgeland, SC
www.tsflightlines.com, www.asflightlines.com
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12-11-2013, 02:46 PM
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Join Date: Feb 2005
Posts: 1,082
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Smoke Injectors
I recently updated my smoke injectors from ones that looked like your old ones that I had fabricated. After seeing my buddies injectors from SA I knew there would be no reason to spend so much on them to pruchase theirs. I found a 1GPM flow SS nozzle from McMaster Carr #3404K79 with 120deg spray pattern. They are only $10.83 ea. A couple bucks for an iron bar from Aviation Depot and a $10 welding job from the welding shop around the corner. Add the fittings and I have two great working injectors for around $50. They have a selection of different flow nozzels so you can match what works with your pump. For my setup I'm getting around .6GPM which gives me a nice smoke trail. Probably wouldn't hurt for this kind of money to have a spare or two in your travel kit for that just in case moment.

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Mike
JAMES AIRCRAFT.com
Flying - RV8 Hot Rod "Drone Killer"
Flying - RV8 "Look'n Good"
RV4 - FAST & FUN! Rebuilt, Flown, Sold
RV-7A Built, Flown, Sold
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12-12-2013, 04:26 PM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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The case has been given an upgrade. Case has a no leak center dowel pressure conversion. The thru bolts will be floating and the seal will be accomplished by O rings around the dowels

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Kahuna
6A, S8 ,
Gold Hill, NC25
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12-12-2013, 04:52 PM
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Join Date: Jan 2005
Location: Georgia / 0GE5 / KSSI
Posts: 399
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I think this thread needs a countdown readout to the next Team AeroDynamix airshow. 
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George
"God does not deduct from one's time on earth that which is spent in the air."
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12-12-2013, 05:08 PM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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New Lycoming Cam
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Kahuna
6A, S8 ,
Gold Hill, NC25
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12-12-2013, 05:14 PM
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Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,400
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The Clean room
Here is where the rebuild is taking place. Called the clean room Like being in an operating room. This is the kinda place I want my engine built in.
And here is how the build begins. The crank stands alone.

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Kahuna
6A, S8 ,
Gold Hill, NC25
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