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Exhaust Springs Annual

Peterk

Well Known Member
I am just completing my first conditional on my RV12. One of the annual recommendations is to re-lube the muffler with anti seize. This of course requires removing the springs. In the plans, it recommends RTV in the spring and on the attaching ends to prevent harmonic vibrations from causing excessive wear.

I have 180 hours on mine after one year which is somewhat excessive but....I did remove the RTV from each of the spring ends and found two (of 8) to be worn more than half-way through. I have ordered more springs and requested Vans to include it as a check on the annual.

These springs have been a breakable item with ultralights for years but they of course safety wired them to prevent "loose spring into prop". I plan to safety wire mine with the RTV now simply because I don't want "loose muffler into cowling." No doubt you could lose 3 or 4 or more before that would happen but they are covered with RTV and would be hard to see each time you looked in there.

Other than that, I have found nothing unusual other than an occasional loose screw and lots of cleaning.
 
John,

No I haven't because its not called for in the ELSA plans and we all did exactly as required. My ultralight friends say they last about 200 hours and I am close to that so I will carry a few spares. Since all 8 would not likely break at the same time, the muffler is not likely to fall if one breaks anyway but I will learn to check them at oil changes. A pusher ultralight would be different...one spring could fly through the prop.
 
I check mine during the oil change, but you are right Pete the RTV makes it impossible to inspect the hooks for wear. What we used to do in my past life as a pusher UL driver is take them all off around 200 hours and inspect them for wear. Pitch them if they are worn 1/2 way through. I always safety wired them on to avoid having a broken spring go through the prop. On our -12's safety wire would be a good idea to avoid having a broken spring fall off the plane. BTW, IMHO putting RTV on them extends the life of the springs at lease double.

The procedure we used for safety wiring them is to simply run a LOOSE loop of safety wire from hook to hook. The only purpose of the wire is to catch the spring if it fails, NOT to hold the two exhaust sections tight.

They make a clamping system that replace the springs if and when the loops wear through. On our UL pushers I converted a couple of planes with these. Pricey, but they do work.

http://www.rotaxparts.net/scripts/prodView.asp?idproduct=324
http://www.rotaxparts.net/scripts/prodView.asp?idproduct=1312

When ordering replacement springs make sure you order the correct length. There are two different lengths, for different Rotax engines.

http://www.rotaxparts.net/scripts/prodView.asp?idproduct=837




If anyone is interesting in an article about these springs and the proper way to safety wire them here ya go....

http://www.ultralightnews.ca/advisories1/exhaustspringtips.htm
 
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Thanks Larry. Good info. I'll try the safety wire for now. The replacement set up is cool and you are right...not cheap!
 
Exhaust joint ball joint conversion

I looked at the sight for the ball joint conversion kit and it says that one kit is required per joint. How many joints require the kit.
 
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