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  #1  
Old 02-03-2020, 11:42 AM
airguy's Avatar
airguy airguy is offline
 
Join Date: Oct 2006
Location: Garden City, Tx
Posts: 5,590
Default Annuals, broken parts, and assistance request

I'm currently in the process of conducting my annual inspection and installing the SDS EM5 engine management hardware, and associated with that I needed to pull the flywheel to drill and tap it for trigger magnets. To pull the flywheel I need to loosen the alternator belt first, and as soon as I took a look at the alternator, before I even loosened the first bolt I knew something wasn't right. The belt angle was wrong and the alternator was obviously not hanging correctly, and as soon as I started to loosen the first bolt the problem was obvious.



And the bolt that was holding it also caught some wear, it was obviously working for some time. 560 hours since new, 193 hours since last annual, and I know I had the alternator off for that annual.



This is the short bracket and bolt that holds the Plane Power 60-amp alternator to the Skytech starter, I'll obviously need to order new examples of each, and thus the question here. Can anyone tell me the appropriate part numbers for these? I put in a question on the Plane Power website but do not have a response yet.

Sidenote - this is why we do GOOD annuals, and not just a paper exercise! If you don't put a wrench on the part before putting a checkmark on the paper, you didn't do anything worth doing.
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Greg Niehues - SEL, IFR, Repairman Cert.
Garden City, TX VAF 2021 dues paid
N16GN flying 900 hrs and counting; IO360, SDS, WWRV200, Dynon HDX, IFD440, G5
Built an off-plan RV9A with too much fuel and too much HP. Should drop dead any minute now.

Last edited by airguy : 02-03-2020 at 03:37 PM.
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  #2  
Old 02-03-2020, 12:10 PM
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Walt Walt is offline
 
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Location: Dallas/Ft Worth, TX
Posts: 6,340
Default

Do yourself a favor and get a B&C now.
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Walt Aronow, DFW, TX (52F)

EXP Aircraft Services LLC
Specializing in RV Condition Inspections, Maintenance, Avionics Upgrades
Dynamic Prop Balancing, Pitot-Static Altmeter/Transponder Certification
FAA Certified Repair Station, AP/IA/FCC GROL, EAA Technical Counselor
Authorized Garmin G3X Dealer/Installer
RV7A built 2004, 2000+ hrs, New Titan IO-370, Bendix Mags
Website: ExpAircraft.com, Email: walt@expaircraft.com, Cell: 972-746-5154
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  #3  
Old 02-03-2020, 12:13 PM
Ralph Inkster Ralph Inkster is offline
 
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Location: Calgary, Alberta
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I just googled 'plane power installation sheet' and came up to a page listing all the pdf sheets. There are part#s on them.
& B&C is another option...
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Last edited by Ralph Inkster : 02-03-2020 at 12:16 PM.
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  #4  
Old 02-03-2020, 12:28 PM
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airguy airguy is offline
 
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Quote:
Originally Posted by Walt View Post
Do yourself a favor and get a B&C now.
I recognize that there is a level of heartburn that exists with several folks with Plane Power - but this is a bracket problem, not an alternator problem. Are you saying PP makes low-quality mounting hardware?
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Greg Niehues - SEL, IFR, Repairman Cert.
Garden City, TX VAF 2021 dues paid
N16GN flying 900 hrs and counting; IO360, SDS, WWRV200, Dynon HDX, IFD440, G5
Built an off-plan RV9A with too much fuel and too much HP. Should drop dead any minute now.
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  #5  
Old 02-03-2020, 01:44 PM
Ralph Inkster Ralph Inkster is offline
 
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Looking at the picture,I?d think the bolt wasn?t tight. Was there a tube spacer between the case bracket forks?
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built a few RVs, rebuilt a few more, hot rodded more, & maintained/updated a big bunch more
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  #6  
Old 02-03-2020, 02:40 PM
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airguy airguy is offline
 
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It took a bit of Google-Fu and about 30 minutes online with a parts distributor but I got the part properly identified and ordered - only $12 plus shipping, a rarity in the aviation parts world that truly surprised me.

Quote:
Originally Posted by Ralph Inkster View Post
Looking at the picture,I’d think the bolt wasn’t tight. Was there a tube spacer between the case bracket forks?
No, this bolts directly to the right hand side of the alternator when viewed from the front of the airplane, and extends from there to the left hand side of the starter, the "A" mounting tab on the Skytech 149NL series. There are no spacers other than a few washers. The broken piece is the starter end of the bracket.
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Greg Niehues - SEL, IFR, Repairman Cert.
Garden City, TX VAF 2021 dues paid
N16GN flying 900 hrs and counting; IO360, SDS, WWRV200, Dynon HDX, IFD440, G5
Built an off-plan RV9A with too much fuel and too much HP. Should drop dead any minute now.
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  #7  
Old 02-03-2020, 07:59 PM
Boyd Birchler Boyd Birchler is offline
 
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Location: IN
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I've seen this type of wear caused by the bolt not being tight enough. The reason it was not tight enough was the use of a drilled bolt with a castellated nut. Torquing properly is a chore because often you could not get to the next castellation point without being too tight and one back ended up too loose. My solution is use a non drilled bolt and a high temperature self locking nut.
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  #8  
Old 02-03-2020, 08:50 PM
Ralph Inkster Ralph Inkster is offline
 
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Location: Calgary, Alberta
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Check carefully when installing the new bracket that it sits flat at each end, & if some washers might be needed to make it sit flat. Not sitting flat would cause bolts to not torque properly and create spot stress points that could break off the end.

I'd also suggest installing a new belt during reassembly.
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built a few RVs, rebuilt a few more, hot rodded more, & maintained/updated a big bunch more
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  #9  
Old 02-04-2020, 08:14 AM
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airguy airguy is offline
 
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Quote:
Originally Posted by Ralph Inkster View Post

I'd also suggest installing a new belt during reassembly.
Absolutely. As much trouble as it is to pull the prop and flywheel, there's no way I am going to put the old belt back on there, they are too cheap.
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Greg Niehues - SEL, IFR, Repairman Cert.
Garden City, TX VAF 2021 dues paid
N16GN flying 900 hrs and counting; IO360, SDS, WWRV200, Dynon HDX, IFD440, G5
Built an off-plan RV9A with too much fuel and too much HP. Should drop dead any minute now.
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  #10  
Old 02-04-2020, 08:57 AM
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bjdecker bjdecker is offline
 
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Location: Georgetown, TX
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Default Part #'s

Bolt -- AN7-42A
Bracket -- 10-1002

and for future reference, you need 450 - 500 inch lbs. of torque on that bolt...
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