Honda 1.8L running on test stand video

[charosenz]

I have been out of state for a few weeks which is why I have not been posting the progress of the project.

At this point I can not be happier with the performance of this engine set up.

The last challenge I had to overcome was with the cooling problems. I believe that most of the high temps I saw were caused by a poor fitting radiator cap. It was not properly pressurizing the system. I installed a mechanical 15 PSI pressure gauge in the panel and learned a lot about how the cooling system was working. In short things work very well. I have to run the engine over 22 inches MAP before it overheats now and the cap releases between 10-15 lbs which seems to be a good pressure. I am not entirely happy with the cheap feel of this radiator cap but it is working well. (keep in mind this is all happening static on ground run ups and I am not flying it).

But I have to wait until I get a larger prop before I can load the engine more, especially to do testing with the T3/T4 turbo.

Another interesting thing is that I learned that LED gauges are great, in low light, but easily get washed out in direct sunlight, but LCD displays work great! LCD has sort of disappeared and are considered "outdated" technology but I am switching my LED gauges to LCD gauges so I can read them in sunlight. Which is another reason why I still like analog (steam) gauges.

The next step is to modify the cowl to fit the engine installation which is going to take me a few weeks (at least). I suspect that this part is a bit too off topic for this thread so I don't really plan to post on that part of the build. If you have questions feel free to ask, or PM.

I have ordered all the parts to install the dual Walbro 155LPH fuel pumps and that will be after or during the cowl mod.

Lots more to do! But all is well.

Charlie

[charosenz]

As I slave away with moding my cowling and remembering that I said I was not going to post about this, I got to thinking that anyone who may decide to venture off in to installing a "Alternative" engine will probably have to do some cowl modification, hence it makse sense to share a bit about this.....

I had to modify my cowling to fit this set up. I had built this cowl to fit a different engine set up. With the R18 Honda, it need to be dropped about 5/8 of an inch and lengthened about 1/2 an inch.

Looking at this photo you may think you see "bondo". Not the case. I use West Systems epoxy and lots of micro balloons with some sillica (cabosil). You will see green foam. This is what I call "flourist" foam that is readily available at any hobby or craft shop. Plus it is very easy to sand and shape. It is excellent and inexpensive when you want add volume and it is NOT structural. So for me it was an excellent choice to add 1/2" to the nose. Then cover with epoxy/micro.



The next photo is a rough fit of the spinner. I have actually done a lot more filling and sanding after this, but it is coming along nicely.



There is a lot more work to do. I will be adding more to the lower cowl and sanding to the correct profile and then cover it all with a layer of glass before painting.

Feel free to ask questions if you want.

Charlie

[charosenz]

Just in case anyone thought I had been relaxing on some far away place - not the case at all! I have been slaving away building up the cowl to fit the engine/prop better.

Here are two photos of the progress. It needs more buffing and polishing but it did turn out fine with me.



Here is one more...



I will be glad when is done, fiberglass is certainly not my specialty, but I would rather do it myself and put up with all the cosmetic flaws than hire it done. To me that is what Experimental Aviation is all about.

I should get my new (72") prop in a few weeks and I am real anxious to do some testing with it....

Charlie

[Piper J3]

Getting close now. Remember to brush cobwebs off flying skills. A lot will be happening on first flights and pilot will need to be very familiar with flying the airframe while sorting engine info. Very interesting to follow this thread with approach and decision making involved.

[charosenz]

Jim,

I wish it was close. But honestly is not. I have probably at least 6 months to go. ...and quite a few non aviation tasks to work on.

But yes. I will get be proficient in type before the first flight.

Charlie

[charosenz]

While waiting on the new prop to arrive and I am working on a variety of small tasks. I have decided to make some changes in the turbo exhaust as well as beginning to upfit the pipes that will go from the turbo to the intercooler to the TB (Throttlebody).

Here are two photos of the new turbo down pipe. It will be attached to the Turbo with a V Band clamp and will have a M14x 1.5tp O2 sensor as well as a bayonet mount EGT probe.






There are a lot of wires and other pipes and tubes that are not yet connected. But over all, I do like the set up of the turnbo down pipe. I was going to bend and route it farther aft, but after more thought, it seems to make more sense to keep it simple. It is about 1" from the silicone coolant lines but I believe this can be protected with a cuff off the downpipe. I know many wrap their turbos and downpipes with ceramic wraps, but I have never been a fan of that, but I will consider it.

Charlie

[Piper J3]

Maybe I missed in earlier post... is turbo for "normalizing" or "boost"?

[charosenz]

I plan to have it boost 5-7 lbs, (40-45 in Hg). The plan is to keep that level up to 10K. This is quite mild (less than half) compared to most boost pressures used on Hondas over all. This will put me somewhere in the neighborhood of 160-180HP. There are factors that may change this once I actually get to flying, but so far this is a conservative set up.

I was very happy with how my intercooler performed on the test stand but on the airframe will be a whole new ball game. Can't wait!!

I did rough in the intercooler today. It actually "sits" quite nicely between the engine and the firewall. I even have a few inches to get a scat duct in there from the front left cowl inlet. I think I will have to fabricate a plenum out of fiberglass and aluminum.

Charlie

[charosenz]

I am continuing to migrate engine systems and components over to the airframe that were functional on the test stand.

Below is a pic of my dual walbro fuel pump system.



I am happy with the set up. For those who may not want to build this piece by piece SDS EFI has a dual pump system that is very compact unit.

I did get my prop today. Very excited to test the engine with this. Unfortunately things are in limbo until I get the fuel system functional and with another trip out of state soon, it may be awhile before I can test the prop.

Ill keep this thread updated as long as there seems to be interest. And since it past over 60k views, I think for now its worth sharing what I am doing.

Charlie

[Bavafa]

Excited about your progress, can't wait for the time you take it up.

With best wishes