Saturday, August 26, 2023

2023/08/23 Squawk updates

 I replaced the ring gear again after breaking some teeth off.   I think what happened is at KSNY, I'd forgotten to turn the fuel pump on when starting so rather than a nice rich mixture, there were dribbles of fuel in the cylinders and I may have just bumped the starter switch lightly instead of letting it crank normally and it went crunch.  

On the Friday Zoom call, Greg Cross advised that there was a new version of Dynon software released in August.  I read through some of the bug fixes, then asked support if I should go ahead and update the software.   Seemed like they were pretty responsive initially but it's unusual to go several days without a response. - Update...just got an email stating that corrupt data on a flash may be the cause, so formatted the flashes & updated the software.

The #1 CHT tends to be the coldest.  Over the last year, I've made several tweaks to the lower ramps but #1 seems to have the largest delta.  Currently #2 is typically the hottest now, sometimes as much as 40F hotter than #1.   The 2nd coolest cylinder is still almost as much as 30F hotter than #1.  Seems like the last lower baffling/ramp tweak went a bit to far.   

I searched on cooling articles in the CSA (now COBA) archives and found ones by Walter Gee  and Doug Kouri where they attended a "cooling party".   The article is in the April 2014 issue.  They used strips glass laid up over a 55 gallon drum, then cut them into 2.5" x 14" strips.  Then positioned the forward edge for #3 cylinder (left side) strip 3" aft of the firewall and ends 12 1/8" back.  The strip for the right (#2&4) starts at the firewall and ends 10" back.  Walter noted that his temps were still higher than the others and his lower cowl leading edge extended into the NACA duct 3" further than the other two planes.  He trimmed it back, covered it with duct tape, flew and his temps were down where the other two planes were.  I'll take some before/after photos of the cowl ramp changes and add to this post later.


-Update on CHT balancing- 3 & 4 are close and 1 & 2 are close but there's about a 30F delta between the pair so I've trimmed a little  off the ramp fences on 3 & 4 to let more cooling air to the aft cylinders.  

Friday, August 18, 2023

Nebraska Trip #2 2023 08/13-16

 Departed T67 a little after 0700 with my wife in the back seat and daughter in the copilot seat.  Ballast was removed from the nose and about 40 lbs. of baggage, snacks & water was in the passenger area.  Almost 40 gallons of fuel on board.  Our daughter Rachel, had just gotten off work and changed out of her scrubs.  She was super excited for this first trip and a her first ride in dad's airplane.  She had ridden with my CFI and me a few times 10 years ago when I was taking lessons in a 172 so had some small airplane experience already.  Her husband came out to see us off.

Right after taking off, LuAnn said, "Houston, we have a problem."  A shirt sleeve had flopped out as the canopy was closed before taking off and was slapping the side of the turtle back.  I opted to land at XBP (with a nice long runway) to retrieve the sleeve and then continue onward.  The landing at XBP was "like a truck" with the high DA and near gross.  The girls thought the landing was fine, but it was the hardest landing I've had as I was coming in a bit slow for the weight & DA.  I mentioned this to Marc later and he advised, "add 5 knots".

Our route takes us under and around some prohibited special use areas near Wichita, Lawton, Altus, Sheppard.  A direct route would go through 9 SUA's.  After we'd reached 6500 MSL (DA was quite a bit higher), I tried what Marc recommended after reading my previous trip report so went WOT and leaned to cruise RPM.  Wow.... 7.8 GPH.  The engine seemed like it was running a bit rougher, but the temps were good except the #4 EGT (I'd misstated in an email to Marc that it was the CHT) blipped high for a bit, so I went ROP for a few minutes, then back to LOP and everything seemed fine.  Bonus... plenty of fuel for the trip as I'd been allowing for about 10 GPH based on previous power settings and temps.

In flight, the copilot side HDX went off line and came back on.  I suspected that the sun shines on it and it overheated.  The pilot side stayed operational and other than showing an alert that the other display was off line, everything seemed fine.  It did it again on the return trip.  

We landed for a few gallons and potty stop at Woodward OK which was unattended on Sunday.  A couple of new Carbon Cubs were stopped for fuel and waiting for a batch of thunderstorms to travel further East to Georgia.  There were several layers of clouds with minimal rain showing on the radar.  

We passed near towns in TX, OK, KS & CO that we have driven through so many times over the years when we would drive several times per year.  Wichita Falls is about an hour drive but only about 25 minutes of flight.  We usually ate lunch in Childress TX and grabbed a sandwich somewhere in KS or CO.

 KSNY had been showing MVFR with a low ceiling, but was seeming like the weather was similar to the previous trip and was forecast to be VFR.  I had to decide over or under as we approached Nebraska.  Since the tops appeared to be under 8500 and broken, opted for staying on top otherwise would be close to scud running under the bases.   We skirted some clouds that were rising and also climbed a little higher to stay clear of the clouds.  Nearing Sidney we saw larger openings and the METAR was showing VFR but with gusty cross winds.  We'd been flying mostly with the autopilot, but occasionally disengaged when we maneuvered through breaks in the clouds.  It was nice to dial in the vertical decent rate while checking weather and alternate airports.  The panel was showing a 43 knots crosswind at 6500'.  There had been no radio calls or traffic showing on ADS-B, so started announcing a straight in landing for 31.  As expected, we got tossed around quite a bit on final but the air was cool, almost chilly with the all the wind.  Welcome to Western Nebraska (almost Wyoming).

George had been out mowing but met us at the hangar again.  I kneeled the plane so the girls could climb out and we threw our bags into the car my sister Dotty & John brought.  George, John & I pushed the plane back into the hangar, but George said he'd need to move it later.  I showed him how to raise and lower the gear, make sure the wheel was lined up to go into the wheel well and also how easy it would be to tip the plane backwards without ballast in the nose.   He asked if I wanted 20 gallons again before departing on Wednesday and confirmed 10 gallons/side.  This should easily get us to our first stop South at Scott City KTQK.  We had lunch in town at Grandma Jo's homestyle restaurant barely beating the church crowd.  They had homemade pies and ice cream for desert.

We spent several days with family and friends making plans for September and later.  The weather was cool enough jeans and long sleeves felt good to someone use to triple digit temps.  On Sunday there were six of us at the farm and taking a gamble, drove dad's Dodge Dynasty to town for lunch since it was the only vehicle with front and back bench seats.  LuAnn & I had driven it the last time we were home, filling up the tank and airing up a low tire.  It started hard a couple of times.  We made it to town and had lunch at a Mexican restaurant.  When we got in the car to leave, it cranked, chugged and died.  Several more attempts and all it would do is crank.  I popped the hood, pulled the intake off the filter and tried again.  Seemed like it wasn't firing, so either no spark or no gas.  A couple of local old timers walked over to provide unsolicited input, probably the best was "get a Ford" even though he was driving a Chrysler product.  A few more tries and the engine fired up.  A younger guy asked how long the car had been sitting and recommended putting some Sea Foam in the tank.  Later, on the suggestion of a pretty experienced mechanic, flipped the ignition switch three times and counted the check engine light flashes to retrieve the codes which indicated the battery had been disconnected and a problem with the cooling fan circuit.  To bad there isn't a "bad gas" code.  My wife informed me we probably shouldn't take that car again until we fix it.

This was a short trip as our daughter had to be back to work on Thursday so planned on being to Sidney at 0700 again.   George gave me the bill for fuel & discounted the hangar fee one night then helped push the plane out and load.  The starter sounded like it didn't smoothly engage on the first start attempt so need to check that.  There was almost a direct cross wind and taking off uphill extended the take off roll some but we had plenty of runway left when we lifted off.  I allowed the airspeed to climb on the upwind and turned downwind as we were above I80.   Set the altitude bug for 7500' and entered direct to KTQK while I punched in the flight plan on the HDX and IFD.  The AP tends to do what you tell it to, so making sure there is a source selected when you push the NAV button.  This seems to be a common oversight of mine so I need to have a sub-list for getting the AP to play well.  It was turbulent also and suspect the roll trim is probably slipping on the torque tube similarly to what the roll trim was doing.  It's on my list to move the AP roll servo out of the hell hole and probably put it behind the pilot's seat back.  Much easier for maintenance and will be easier to eliminate the slipping issue.

The winds weren't optimal for the trip home, but looked like 7500' was about the best we were going to get without O2.   After reaching cruising altitude, went LOP again and appreciated that the fuel range would be extended.   In a little bit over an hour, landed straight in on 17 at KTQK, had to back taxi, then to the pump and kneeled for fuel.  The girls found their way into the FBO while the line guy came out and asked, "Weren't you here a couple weeks ago?"  While chatting and me trying to do some "if the winds are bad, how much fuel do I need math" the pump's credit card authorization timed out despite me slowly punching buttons.  I put in 12 gallons of fuel putting us a little over 30 gallons which should be enough for some wind & 30 minute reserve.   The last 150 miles of the trip is near some nice airports as alternates too.

After we departed Scott City, the copilot side HDX went off line, rebooted and came back on.  Doesn't seem like it should be temp causing it so opened a support ticket when we got home.  I have FlyQ running on a tablet and phone as well, plus the SDS panel reads out some of the engine parameters.   

Rachel had dozed off in the copilot seat but I nudged her and pointed at an Air Force tanker coming towards and 3000' above us.  I wondered if it could be Mark Richardson out of Altus?  The waypoints I use keep us between the SUA's and we stay under a couple of ones that have a floor of 8500'.   Near Sheppard, ADS-B was "IRON-11,12,13 & 14" doing some runs within our 15 NM ring on the screen.   I could see some dust or smoke rising from the ground in that prohibited area we were passing by so took a photo.  I took a couple of screen shots and recall several friends claiming they fly VFR through the MOAs.  This probably wouldn't have been a good day to do that.

500' below a MOA.  F16's kicking up dirt.



The OAT was staying at moderate temps but it was getting pretty bumpy as we began to descend near Bowie for T67.  The METAR for KAFW had me thinking Rwy 32 would be preferred with a crosswind from the NE at T67 but radio chatter revealed 14 was being used and quite busy.   I watched for traffic and made announcements, even extended my downwind after a tail dragger (without ADS-B) announced he was taking off when I was about to call my base.  After extending, I announced base to final and the tail dragger said he was taking off and someone advised, "There's a plane on short final" so he held and announced he needs to get his hearing checked.   As usual there was a fairly common wind shear on final for Rwy 14 when the wind is out of the East or West.  I landed quite a bit faster than usual and got on the brakes hard initially to get slowed down and rolled to the end.

I had my daughter hit the hangar door remote button to open the door and I got a little to close to the bifold door so had to quickly turn 90 degrees to keep from hitting the top of the winglet before door opened more.  I kneeled the plane most of the way, and as the girls were starting to unload in the taxiway in front of the hangar, the nose "clunked" when the wheel pivoted.  Dang it.  I need to remember to straighten that wheel out as soon as I climb out.   We landed with enough gas to easily make it to 1/2 dozen alternate airports so was happy with my planning to not haul more than we needed.   The ambient temp was tolerable (90's) when we landed.

We're all so thankful to make this trip in about 3.5 hours of flight time, around 4 hours with one stop.  We used to spend 12 hours driving to make this trip one way, multiple times a year.  Weather and payload will be our deciding factors for future trips.  

The only major squawk so far is the copilot side panel resetting and the starter engaging.  I pulled the logs and open a support ticket via email.  My wife mentioned the pad that she leans back against on the spar had slipped.  I'd still felt some air around my feet and ankles so will try to find if it's through the top covers or landing gear cover that is leaking.  

I'd been running the oil at 8 quarts but was getting some blowing out the breather so started running it at 6 per several folks suggestions and that seems to be working well.   The residue in the exhaust pipes is a lighter shade of grey after running LOP.  And there's smashed bugs to clean off.  



Thursday, August 10, 2023

8/8/2023 Nebraska Trip

 We departed T67 at 7 AM with 45 gallons, take off weight near 2000 lbs. for a 1.5 hour flight to KWWR Woodward OK as a mid-point stop to KSNY.  We arrived with about 31 gallons.  LuAnn rode in the back, so there was about 50 lbs. of ballast in the nose.  The runway, fuel pumps & FBO at WWR were in great shape.  The tarmac near the fuel pumps needs to be sealed.  

Tach 62.1  - 63.6

Hobbs 88.9  - 90.5

Altitude bug was set on 6500.  IAS was about 147, TAS 166.  RPM varied between 2480 in cruise climb to 2532.  

Fuel Flow showed 14.4 GPH on take off, 13 climb and around 10 GPH in cruise.  CHT's and Oil temps were good. Amps were about 11.  MAP was mostly at 21.7.

When we left Woodward, there were some showers showing on the screen and visible in the air.  We climbed to 6500 initially, then 8500 to go over a string of clouds.   Sidney was reporting a low ceiling, so I went East and dropped down to pattern altitude over I80 where the clouds were broken and could see towards the West that Sidney was not currently viable.  We climbed back up over the clouds at 7500, transitioned to the West.   LuAnn texted my sister that we would cruise around for 20 minutes and divert to Scottsbluff if Sidney hadn't cleared, which is what we did.  We circled Chimney Rock near Bayard NE and got some nice photos.  It was too cloudy further East to see Court House and Jail Rock.

We got 20 gallons of fuel at BFF.   One of the runways was closed which I didn't recall seeing in the NOTAMs.  My sister reported a plane had just landed at Sidney and the ceiling was raising from 500 to 800 and they were starting to see the sun pop through.  We taxied to RWY 05, OAT was about 85F, DALT was about 6400' with minimal wind.  Taking off, when the nose lifted the rear mains lifted and we climbed a few feet above the runway but kind of "mushed" and the mains touched again.  I may have been kicking the rudders out just a little bit too.  When the mains lifted again, I stayed in ground effect until the IAS was climbing well above 80 knots.  My first lessons were back in the 1980's were at AIA and SNY.  This performance reminded me of a white knuckle landing/go around I had with about 14 hours under my belt.  I'd also flown right seat on CAP sorties in a 182 in the area and am aware where pilots used to inadvertently have CFIT along I80 East of Sidney when scud running.

We flew along the North Platte River back towards Chimney Rock, then towards Bridgeport but the clouds were still low there.  We did get close enough to Court House and Jail Rock to get some photos.  We turned South towards Dalton and got some photos of farms and a video flying over my dad's place.  When we neared Sidney a Baron was announcing he was taxiing for departure so I followed Hwy 385 to enter a downwind.   I was a bit to high on final so decided to go around and give two of my sisters a bit of a show.   The second attempt was much better on the very long and wide runway.  George met us on the ramp and directed us to the hangar where we unloaded and pushed the Cozy in for the 4 day stay.

We spent a few days at the farm doing maintenance and attended a reunion on Sunday.  On Monday, Dotty & John gave us a ride to Sidney.   I chatted with George about getting a hangar and got my name on the list.  They had added 20 gallons of fuel the day before.  We loaded the plane, said our goodbyes and departed for Scott City.

Approaching Scott City and looking at the runway saw that we'd have to back taxi if we landed from the North.  Since there was no wind reported, decided to land from the South.  I was way to high again so went around.  We stretched and decided to add 6 gallons even though there was enough left to get home.  We watched a student solo before taking off to the South.

The radar was showing splotches of green along the Red River, some was at pretty high altitudes above us and we were at 9500.   I monitored the Class D and other airports as we were passing.  We started descending near Bowie and were at 2500 by Copeland.  The turbulence was noteworthy and a wind shear on final was not unexpected.  LuAnn still gave me an 8/10 on the landing. It was a 2 hour 22 minute flight from Scott City.

LuAnn said she'd like a sun shade for the back window and some non-skid on the floor to make it easier to get out.  I applied some strips of 3M non-skid that Karl Riley gave me.  LuAnn ordered a shade for the window.  The pilot mic audio was occasionally scratchy and I found one of the wires in the headset plug was broken.  There was cold air on my feet so sealed some openings around the canard cover.   The heater worked well to keep my legs warm with the OAT at 57F when we left KSNY.

I fixed the headset, changed oil and attended to the NG3 nose gear.  The oil filter pleats looked as expected with a low time engine.  There were some tiny shiny particles visible but very similar to a new 540's filter I had been inspecting since it was new.  I captured some oil for analysis.  

The AN4-15 bolt that the actuator rotates on was found to be a bit to short and the bolt threads had mashed, giving the components some unwanted slop and resulting in some clunking and popping. I replaced the bolt with an AN4-17, and added a few thick washers under the nut.  I sanded about 1" above and below the NG3 and put some flox and BID to provide a little more containment than just the (non-plans but recommended) AN3 bolt through the strut.  I also reorganized the headset jacks so that the pilot's jacks weren't getting bumped by the canopy's gas strut.  I moved the pilot's left rudder peg one notch forward.

Hobbs 97.4  Tach 70.4.

I did have the copilot HDX1100 reset once in flight and there were two files from the EFIS where there was no GPS data.  I'll check the connector to make sure it's tight.   I still tend to have some trouble initially with the Autopilot going into NAV mode where it seems to want to go into a continuous turn.  A friend suggested going into heading and altitude mode, then when it stabilizes, go into NAV mode.  The roll trim seems to work much better now.


Wednesday, August 2, 2023

#OSH23 Squawks

 Right roll - found the roll trim spring Adel clamp on the torque tube slipping.   Made a new bracket for two Adel clamps.

NG3 (nose gear strut shackle) has loosened after a almost gear up and taxiing through the grass at OSH.  I'd installed a bolt through it so it hasn't slipped.  Recent posts indicate this isn't the best solution as it can weaken the strut.  Maybe I'll get a new strut and associated parts.  Availability of the electric nose lift appears to be less than optimal.  I chatted with Russ and know that Jet Guys have been installing some sort of hydraulic actuator but they do the installation.  A search found this H-Track Electro-Hydraulic Linear Actuator that would seem to be a viable alternative to the current solutions.  https://www.thomsonlinear.com/en/products/linear-actuators/h-track

The heater control cable became disengaged from the butterfly's arm.  I made a temporary repair and include it in the list of things I want to change in the hell hole.  

Occasionally, the third canopy latch doesn't catch.  It is probably operator error when I'm closing the canopy I start to latch before the canopy is fully closed.   I think I posted previously that the magnet security sensor had failed so replaced it already.  I think the magnet was to far away allowing the contacts to chatter and ultimately fail.  A microswitch or optical sensor would probably be better.

The iPad didn't charge well when running the FlyQEFB app.  The VPX showed the amperage for the audio panel (PS Engineering) go up .6 Amp when the tablet was plugged in.  Suspect heat and maybe a cheap USB-C cable are why the current was limited.  Even the wall wart didn't seem to keep up with the power getting sucked by the app later when testing at home.  I'll watch the ipad power consumption stats and give some feedback to Seattle Avionics.