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  #1  
Old 08-25-2020, 01:10 PM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 1,198
Default SB-00005 released: Inspect and replace original RV-12 exhaust pipes

Today we published a new RV-12 service bulletin, SB-00005. This document applies only to the original/legacy RV-12 with the Rotax 912 ULS engine. It does not apply to the RV-12iS aircraft.

SB-00005 supersedes and replaces a prior service bulletin, SB 19-03-22. Regardless of whether one has previously made the changes described in SB 19-03-22, you will need to perform the SB-00005 inpsection and take any necessary actions. If you've made the SB 19-03-22 change in the past, you should also read the note below regarding an available price reduction on the SB-00005 kit for people who have purchased a replacement SB-00017-1.

This service bulletin requires inspection of the #2 cylinder exhaust pipe to determine if the installed pipe is affected by this bulletin. If it is an affected part, the bulletin then requires inspection of the EX-00017 or EX-00017-1 exhaust pipe. If cracks are found, the owner/maintainer must replace both the EX-00017/00017-1 and the EX-00015 pipes, as described in the document.

Becuase we have observed multiple instances of cracking of the affected exhaust pipes at a weld joint, and because a broken pipe could potentially result in damage and/or introduction of harmful gases into the cockpit, the bulletin requires that either a) the pipes be replaced, or b) that they be inspected for cracks every 25 hours and a carbon monoxide (CO) detection device be used in the aircraft. Van's has a kit for installation of the Aithre CO detector, or the owner may choose to use another aviation-appropriate CO detector option.

The SB-00005 kit, which contains the necessary parts and hardware, is available to order from Van's. It includes new exhaust pipes/tubes for both forward cylinders as well as replacement exhaust nuts. The new EX-00015-1 is a two-part pipe assembly that incorporates a slip joint. The new EX-00017-2 is a one-part pipe assembly without a weld seam in the affected location. Note that you must use both of these new parts together (do not install just one or the other).

Note to owners who have previously purchased a EX-00017-1 replacement pipe from the earlier service bulletin: If you have purchased and received an EX-00017-1 pipe assembly in the past, please contact Van's directly to place your order. Van's will reduce the prices of the SB-00005 kit by 50% for people in this group. This is financially equivalent to receiving the newest #2 cylinder replacement pipe at no charge. Note that Van's does not mark up SB kits when issues for safety reasons - we sell them at approximately our cost (and in some cases at a significant loss). That is the case with this SB kit.

Note to all owners of the original/legacy RV-12 aircraft: Van's will also be releasing an entirely new exhaust system for the original/legacy RV-12 later this year. It will be constructued using certain parts common to the RV-12iS exhaust, plus certain new parts required to fit the legacy engine and aircraft. Obviously, the cost of a complete replacement exhaust system will be significantly higher than the cost of replacing two pipes, but we wanted to be sure to inform owners now of the future option so they can take it into account in the decision process. If you continue to fly and inspect every 25 hours, be sure to install a CO detector, per the service bulletin.
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Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)

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  #2  
Old 08-25-2020, 01:39 PM
DHeal DHeal is offline
 
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Location: Windsor, California
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Default

Greg --

Will the "entirely new exhaust system for the original/legacy RV-12" incorporate the fix to move the original muffler further back away from the oil cooler? Estimated cost?
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EAA #23982 (circa 1965) - EAA Technical Counselor and Flight Advisor; CFI - A&I
RV-12 E-LSA #120496 (SV w/ AP and ADS-B 2020) - N124DH flying since March 2014 - 1,170+ hours (as of May 2022)!
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Last edited by DHeal : 08-25-2020 at 01:47 PM.
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  #3  
Old 08-25-2020, 05:37 PM
Piper J3's Avatar
Piper J3 Piper J3 is offline
 
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Location: Hinckley, Ohio
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Default

Quote:
Originally Posted by DHeal View Post
Greg --

Will the "entirely new exhaust system for the original/legacy RV-12" incorporate the fix to move the original muffler further back away from the oil cooler? Estimated cost?
I don't think the muffler can be moved rearward - it would interfere with the crankcase oil drain elbow. Maybe if a banjo fitting is incorporated...
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Jim Stricker - EAA #499867
PPL/ASEL 1970 - Sport Pilot since 2007
80 hrs Flying Aeronca Chief 11AC N86203
1130 hrs Flying 46 Piper J-3 Cub N6841H
Bought Flying RV-12 #120058 Oct 2015 with 48TT - Hobbs now 790

LSRM-A Certificate 2016 for RV-12 N633CM
Special Thanks... EJ Trucks - USN Crew Chief A-4 Skyhawk
MJ Stricker (Father - CFI) - USAAF 1st Lt. Captain B-17H

Last edited by Piper J3 : 08-25-2020 at 05:39 PM.
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  #4  
Old 08-25-2020, 05:38 PM
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Piper J3 Piper J3 is offline
 
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Looks like SB-00005 = one or two social security checks...
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Jim Stricker - EAA #499867
PPL/ASEL 1970 - Sport Pilot since 2007
80 hrs Flying Aeronca Chief 11AC N86203
1130 hrs Flying 46 Piper J-3 Cub N6841H
Bought Flying RV-12 #120058 Oct 2015 with 48TT - Hobbs now 790

LSRM-A Certificate 2016 for RV-12 N633CM
Special Thanks... EJ Trucks - USN Crew Chief A-4 Skyhawk
MJ Stricker (Father - CFI) - USAAF 1st Lt. Captain B-17H
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  #5  
Old 08-25-2020, 10:08 PM
PMLviator PMLviator is offline
 
Join Date: Mar 2014
Location: Groveland CA
Posts: 63
Default EX-00015-1 slip joint

It seems the EX-00015-1 slip joint is in reverse. Shouldn't it be male into female so the exhaust fumes flow past the joint? Not female into male where the fumes can come out of the joint seam.
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  #6  
Old 08-26-2020, 04:58 AM
bernsbm bernsbm is offline
 
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Location: Mequon, WI
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Greg,

Appreciate the information and discounted price for those of us who have installed the EX-00017-1. Can you elaborate on what problems/concerns the new exhaust system will address beyond those covered by installing the new exhaust pipes for cylinders 1 and 2? This will help us better understand which replacement option to choose.

Thanks
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N12BB RV12 Skyview flying since Oct 2016 (Sold)
N122B RV12iS Garmin flying since Oct 2020
https://eaabuilderslog.org?s=N122B
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  #7  
Old 08-26-2020, 12:15 PM
printbr printbr is offline
 
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Location: Richland, WA
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If the EXH 1202 requires no replacements why don't they just replace the EX 0017's with the EXH 1202?
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  #8  
Old 08-26-2020, 05:38 PM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
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Location: Aurora, OR
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Default

Quote:
Originally Posted by bernsbm View Post
Appreciate the information and discounted price for those of us who have installed the EX-00017-1. Can you elaborate on what problems/concerns the new exhaust system will address beyond those covered by installing the new exhaust pipes for cylinders 1 and 2? This will help us better understand which replacement option to choose.

The new system will use the Rotax 912iS muffler, with the exhaust exit pipe located in a position appropriate to the legacy RV-12. This muffler’s ball-joint connections (where the pipes attach with springs) are of a more robust design. It weighs 1.15 pounds more than the legacy exhaust system. And it sounds nice.

Quote:
Originally Posted by DHeal View Post
Will the "entirely new exhaust system for the original/legacy RV-12" incorporate the fix to move the original muffler further back away from the oil cooler? Estimated cost?
The new exhaust that we will release later this year uses the same aft placement for oil cooling performance reasons as the most-recent legacy exhaust system. The new exhaust system will be called EX-00044 and is based upon the 912iS exhaust system. It will sell for approximately $1800.00. This is the same price as the current 912iS exhaust system used on the RV-12iS.

Quote:
Originally Posted by printbr View Post
If the EXH 1202 requires no replacements why don't they just replace the EX 0017's with the EXH 1202?
The EXH 1202 is a part that was included in the original, first-generation RV-12 exhaust system, which had the muffler located closer to the oil cooler. That system is no longer produced, and was replaced some time ago by the second-generation RV-12 exhaust, which included the EX-00017 pipe and relocated the muffler further aft to improve oil cooling performance. The parts are not compatible nor interchangeable and it is valuable and important to retain the distance between the oil cooler and the muffler.

Quote:
Originally Posted by NinerBikes View Post
Sounds like they went to a 1 piece part again for headers for cyls 1 and 2. No welded together segments?
The Cylinder #1 pipe incorporates two slip joints and no welded together segments. There are no joints or welded together segments in the #2 pipe. This is the case on both the retrofit pipes we released this week, as well as the to-be-released EX-00044 exhaust system.

Quote:
Originally Posted by PMLviator View Post
It seems the EX-00015-1 slip joint is in reverse. Shouldn't it be male into female so the exhaust fumes flow past the joint? Not female into male where the fumes can come out of the joint seam.
The direction of the joints was examined during design. We determined the position and direction of the joints was not a factor given the flow volume and pressures of the system. Direction of the slip joints in this system does not affect performance, flow or leak rate.
__________________
Greg Hughes - Van's Aircraft
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)


Last edited by greghughespdx : 08-26-2020 at 06:36 PM.
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  #9  
Old 08-26-2020, 06:57 PM
Piper J3's Avatar
Piper J3 Piper J3 is offline
 
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Iím pretty good at cyphering Service Bulletins and Airworthiness Directives (back when I owned a CUB) but this SB is a bit of a head scratcher. Sort of like a Chinese menu where you take one from column A and two from column B.

My RV-12 is a very early SN with original exhaust. Both front stacks are one-piece mandrel bent tubing with no welded seams so I guess I have EXH-1202 #2 Exhaust, and if thatís the case, I reinstall the cowling.

Iím trying to figure out why there is so many iterations. I think Vanís moved the muffler back and probably down at some point to increase clearance to the oil cooler. What Iím puzzled about is why didnít they stay with a one-piece mandrel bent design? The later design exhaust stacks look kind of hideous...
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Jim Stricker - EAA #499867
PPL/ASEL 1970 - Sport Pilot since 2007
80 hrs Flying Aeronca Chief 11AC N86203
1130 hrs Flying 46 Piper J-3 Cub N6841H
Bought Flying RV-12 #120058 Oct 2015 with 48TT - Hobbs now 790

LSRM-A Certificate 2016 for RV-12 N633CM
Special Thanks... EJ Trucks - USN Crew Chief A-4 Skyhawk
MJ Stricker (Father - CFI) - USAAF 1st Lt. Captain B-17H
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  #10  
Old 08-26-2020, 07:16 PM
Mich48041 Mich48041 is offline
 
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Location: Riley TWP MI
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I agree with you Jim. It is a head scratcher. A chart or graph is needed
with columns and rows that contain part numbers and characteristics.
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