Exciting landing and major mess

CosmicHerb · #1 01-29-2011, 06:55 PM

On Saturday I thought I would fly the pattern for a few hours with the wind going right down the runway and I am 10 hours into my test flight phase. My 7A was flying perfectly and I went around e pattern and did a touch and go. On the second time around as I entered the downwind leg I noticed some liquid on the wind shield within a few seconds it started to completely cover the front of the canopy and I had no forward vision. The engine was still running like normal and I noticed that it still had 60 psi on the oil pressure gauge when I could tell it was oil all over the front of the canopy.

I announced I had an emergency over the radio and immediately began setting up to land. I decided to cut the base short and turn early to the runway. I was worried the engine may quit at any time. I kept looking at the engine gauges and then were all in the green and the oil pressure was steady at 60 psi.

I knew the landing was going to be tricky because by this point I couldn't see out the front of the canopy. As I was setting up on final, I realized my biggest problem was I had too much speed and was high. I put it into a slip which also allowed me to look out the side of the canopy and see the runway. I used the flaps to help slow me down and at flare height I lined up with the runway out the corner of the window and held it off until it gently touched down. Surprisingly the landing went perfect no bounce or anything.

I then taxied over to the hangar by looking out the side and pulled in front of the hangar, shutdown the engine and began to breath again. Once I got out there was oil all over the plane and it was dripping off the prop.

I wiped down the plane as best I could and removed the cowl and was surprised to find very little oil in the engine compartment. I could tell it was all coming from the prop. I pulled the spinner which was full of oil and realized it was coming from inside the prop.I then removed the prop and found the problem. I had converted the engine from a constant speed prop to a fixed pitch. I had punched the hole in the interior plug but it was the front plug that had come out and where the oil was coming from.

My question is, did I install it wrong or is there a better method so this will never happen again? This could have been so much worse if I didn't happen to be in the pattern at a familiar airport. I installed it and them sealed around it with pro seal. The engine has about 20 hours on it so it didn't happen immediately. I had changed the oil a couple days ago and have flown 3 hours after the oil change before it failed. As I mentioned before I still had 60 psi on the oil pressure gauge all the way to the hangar and the engine was behaving normally both before and after the plug failed. At least as far as my mental state at the time would notice.

Any advice or suggestions would be appreciated.

DakotaHawk · #2 01-29-2011, 07:38 PM

You did the most important thing... FLY THE PLANE!

Good job getting it back on the ground safely. Great news that you didn't trash the engine. As I was reading, I was afraid that this was going to end up with bent aluminum, very happy to see that you only got your first dose of oil spray.

As for the plug, I think I would get an A&P to install the new one. Might cost you a little cash, but I would be more comfortable knowing that the front oil plug has been properly installed and seated.

az_gila · #3 01-29-2011, 08:04 PM

If the dimensions are right, the seal should turn from an "outie" to an "innie" when installed with a hammer blow.

If it's seated down against the step in the crankshaft there isn't much more you can do...

plehrke · #4 01-29-2011, 08:11 PM

Quote:

Originally Posted by CosmicHerb

it was the front plug that had come out and where the oil was coming from.

Had the same thing happen at 110 hours except I only had a few streaks of oil on the windshield. You need to get the right tool [and maybe an A&P that has done one before] to seat the plug. I made one out of a pipe to make sure the edges are seated before putting the dent in the middle.

charger81 · #5 01-29-2011, 09:28 PM

You got it on the ground safely. I too thought this was going to result in bent aluminum. A great test of your skills but not one I would wish on anyone.

Congrats on a safe outcome.

rv8ch · #6 01-30-2011, 01:10 AM

I can't offer much more than you have already read, but just wanted to say very impressive first post!

rvsxer · #7 01-30-2011, 04:51 AM

I had the same thing happen on an RV-6A test flight (for a friend, Paul) after an engine overhaul. The overhauled crankshaft had been received from the vendor set up for a C/S prop, with the inner plug installed. The engine builder had ordered it converted to FP for a Sensenich, assumed it had been, and just went ahead and installed the outer plug at the end of the engine assembly.
On the first flight, the oil supply to the crankshaft had nowhere to go and pushed the front plug out. Apparently the preflight engine runs hadn't produced enough oil pressure to do that. After takeoff on downwind, I saw the oil on the windscreen and put in a little right rudder to keep it to the right side. I told Paul (who was with me) to keep an eye on the oil pressure, traffic, and radio while I flew. Uneventful landing and a big mess to clean up...

N8RV · #8 01-30-2011, 08:19 AM

As has already been said, congratulations on keeping your head in the game and getting back on terra firma. And welcome to VAF. Great first post!

jrs14855 · #9 01-30-2011, 10:43 AM

I think the biggest issue with these plugs is using an improper tool, and/or not hitting the plug hard enough. Lycoming does not specify any sealant on the plug. I am going to investigate the possible use of sealant. I believe that the tool should be at least half the diameter of the plug, with a very slight smooth radius on the face. I have to disagree with the A&P comments. The average A&P is no better equipped to deal with this than the average homebuilder. The A&P is just as likely to use an improper tool. If the A&P has extensive experience with Lyc engines, then it would be appropriate to use the A&P.

CosmicHerb · #10 01-30-2011, 01:46 PM

Thank you for the feedback. I appreciate the comments and even though this is my first post I have been avidly reading for many years and have gained valuable inspiration from this site.

I also thought that after the incident I might be hesitant about flying again but instead all I think about is getting the plane fixed and back in the sky. Flying is like an addiction I can't get enough of.