Saturday, April 30, 2022

Update 4/28/22

 Test ran the engine today with the cowls on.  Starting, left the mixture knob slightly lean and motor fired in about 5 seconds.  Starter disengaged.  The AFR sensor doesn't seem to be reading correctly so the controller possibly is bad.

After shutting the engine down, the prop stopped vertically and had soot on the blades.  I re-clocked the prop to 1/7 o-clock, torqued the prop bolts to 40 ft. lbs. and safety wired them.

My Insurance Agent emailed me that one of the carriers wants me to have about 10 more hours total time.  Other members in the builder/flier group have recently been insured with Avemco.   Regardless, the wind has been gusting to much to safely taxi test.

I'm spending some time repairing a 12" spinner for a friend.  Will likely pop a mold and make a new one.



Friday, April 22, 2022

Update 4/22/2022

 The brake temp sensors are installed and the belly leg gear cover is installed.   The left sensor was reading erroneously and cleared after disconnecting, and checking continuity etc.   Acted like the issue was possibly with the EMS220 port.  They seem to be reading ambient temp correctly.   Once heated, it takes awhile for them to cool.   A little less mass around the probe would be better. 

The coils are reconnected but the right/bottom coil still needs the new 4 connection harness installed, found one alternator bolt hadn't been tightened.  The IP cover is reinstalled.   Still need to rig a canopy switch.

The FAA mailed me the repairman certificate yesterday.   On the back of the card is the Cozy's serial number that the certificate is designated for.


Thursday, April 21, 2022

Update 04/21/2022

 I made some temp sensors using scrap thermocouple wire, aluminum tubing, nut plates and JB Weld.   They'll be mounted to the leg heat shields to help approximate how hot the brakes/gear legs are getting.

The Dynon EMS220 module had unused temperature sensing ports normally used for cylinders 5 and 6.   Added widgets to the 100%, 50% and bottom band engine screeens.


Wednesday, April 20, 2022

Update 04/20/2022

Obligatory social gatherings have dominated a majority of free time lately, so will try to get some updates here:

Another good ring gear is on.  A .020" spacer for the Skytec 149NL starter was made so it will disengage properly.   There's a FAQ on Skytec's page that there's an issue with Superior ring gears and this starter.  We ran the starter multiple times (mostly not under compression) with the shim and it disengages now.  

The ring gear carrier was marked with yellow tape to identify the position of the pistons.  Timing lights were used to confirm that spark plugs were firing.  I wasn't getting a light on the bottom #4 cylinder so borrowed a couple other timing lights.  Ultimately, I replaced the coil since it seemed to be intermittent, but now think there were other factors such as where the timing light pick up was connected (near the spark plug or closer to the coil).  Two of the timing lights we used had arrows on the inductive pick up so were sensitive to the polarity of the field off the plug wire.   The newer light I had would work either direction.   Ross advised that the coils used were for a 2002 Subaru and offered to send a replacement and connector.   I could get a coil next day locally and found Oreilly Auto stocked the "Standard  Ignition  4 terminal Connector" - part S1931. 

I'd decided that running the primary ECU and coil through the VPX wasn't the optimum configuration so added a fuse/terminal block under the pilot seat where the Essential Buss is located and that is it's power source now.   Both ECU's are reading identical voltage now whereas, before the A ECU was two tenths of a volt less than the B ECU.   The VPX was reconfigured with the SDS A ECU and top coil circuits deleted.  The panel switches for the coil and ECU were fed off the fuse panel.

On my "nice to have" list were temp sensors to get an idea how hot the brakes were getting.  The Dynon EMS 220 has open ports (normally used for 6 cylinder engines)  that I ran the wires for brakes and engine compartment.   Some of the sensors were stupid expensive, unavailable or not quite what I wanted.  YouTube had some DIY instructions on making thermocouples so I made one and it was within a few degrees of my DVM's probe.  I used some 3/8" aluminum tubing to make the housing and mounted nutplates.  The thermocouples are bedded in some JB Weld, leaving air pockets inside the tubing to reduce the mass and hopefully improve response time.  I know using dissimilar metals for the electrical connections will add some error to the readings, but I'm looking for "will it melt the leg gear" or is it "cool to the touch" types of readings when taxiing.  The probes will mount on opposite side of the rotor on the heat shields.

Anticipate an engine run/test and low speed taxi test when the weather allows.

Our local airport T67's LiveATC.net feed was down for a year so I contacted the original host and relocated the equipment to my hangar and got it on line again.   Also my buddy's Comanche is down for it's annual and 1000 hour gear AD.  When I open the hangar door, can expect 3 or 4 visitors popping in so I have to be diligent to finish tasks after getting distracted.



Thursday, April 14, 2022

Brake Heat Shield Temperature Sensors

 

Many of the surface mount thermocouples were either out of stock or high priced so I decided to try making some using left over thermocouple wire.

The ends of the wires were stripped, twisted together and clamped with forceps.  A piece of graphite from a carpenter's pencil was held in a vice.  Jumper cables were attached to a lawn mower battery, the vice and forceps.  Touching the ends of the thermocouple wires to the graphite block fused the wires together.  






3/8" fuel line were cut into about 1.5" long pieces, then cut part way lengthwise and opened up like a T.   Nutplates were attached.  JB Weld (which is non-conductive) was used to pot the thermocouple probe, keeping the bare wire off the bare metal.  I tried to use a minimum amount of JB Weld to keep the mass of the probe minimal.

The probes measured within 1 degree F of the test meter's probe.

I drilled a screw hole in the heat shields aft and just above the brake rotor to make it easy to mount and access.  



Wires had been run down the gear legs previously in anticipation the probes.  They go up through the hell hole to the Dynon EMS 220 module.





How to set up Dynon widgets: