Tuesday, April 23, 2024

4/22/2024 Trip Report - Livingston TX

 The weather and schedules were finally conducive to haul the Sunmate seat cushion foam and patterns to Livingston TX 00R.   I preflighted the plane the night before, adding a little air to the nose tire, updated the Skyview database.  I filed a flight plan from Hicks T67 to Livingston 00R using FlyQ EFB the night before.

An email to Richard (the upholsterer) was sent to reconfirm I'd be on my way and I received his reply Monday morning.

Occasionally leg cramps have bothered me so I try to remember to  use Theraworx (for muscle cramps) before longer flights.  I also carry some homeopathic cramp remedy which are small tablets that go under your tongue, and always carry water.  

Monday morning I made a quick breakfast, checked the weather, pushed the plane out, started and taxied.  A few students were already in the pattern.  I checked my pre-take off list and set Com2 to Meacham, anticipating a transition immediately after departing Hicks.    After taking off, I called Meacham and the tower responded "Do you have a working transponder?".   I'm already going about 150 KTAS, climbing to 2500.  I make a quick 180 and respond to the tower that I'm checking...   Usually the transponder is set to Automatic but it had manually been set to Standby.  I hit the VFR button, but still showed Standby...so hit the Automatic button and the tower advised they saw me going North near Hicks.   She asks if I'd still like to transition at 2500, showing a Cessna at 2000' 1/2 mile south of me and I reply affirmative.  She clears me through on the West side of the field.

The Avidyne IFD540 alert audio is announcing "Airspace ahead".  This is new to me after spending a few days during the CI, pinning the wires that hadn't been installed by the shop that built the audio harness.  I hadn't worried about it much as getting my IFR certification has been lower on my priorities.  I'd suspected that the lack of alert audio was a configuration issue but that would have been to easy.

After passing South through KFTW's airspace, the tower approved the frequency change and apologized for the confusion which I replied, "The pleasure was ALL mine!"  lol  

I was monitoring several frequencies and the air space was plenty busy.  I opted to skirt around Arlington then climb after exiting out from under Class B.  I'd been hand flying and finally dialed in the altitude and engaged the AP in Nav mode.   After skirting Arlington, headed direct to 00R.  

FlyQ EFB has a nice "winds" feature under the weather tab.  It showed if I climbed up to 5500, I'd avoid a head wind.  It was moderately bumpy so had the power pulled back yet was showing some respectable ground speed.  I watched the map along with the roads and airports nearby, monitored local airport radio traffic occasionally until the heterodyning crosstalk made it difficult to listen to, so turned the volume down.

Nearing Lake Livingston (5th largest lake in TX) from the Northwest when descending to TPA, there is mostly wetlands and trees.  I disengaged the AP about 15 miles out in a 800 FPM decent.  A Cherokee called 7 miles out shooting an RNAV from the South as I landed straight in on Rwy 12 on the 3700' runway.   Trees are on the ends of both runways.  There is no taxiway so back taxied to the ramp.   The Cherokee did a low approach and exited to the East.

I closed my flight plan and called Richard (the upholstery guy).  I repositioned the plane closer to the vehicle entrance and heard a firetruck siren, then a medivac chopper approaching. I double checked the ELT to make sure it wasn't going off.   Soon an ambulance arrived, then Richard.   After a few minutes, the patient on an ambulance was loaded into the medivac and it departed.



Richard took photos of the interior and we loaded up the boxes of foam and patterns, then drove to his shop.   One of his customers had recently had some seats done for a Ferrari.  He showed me different types of stitching and material.  We talked about pricing and (ouch) I had some sticker shock.  Not terribly surprised though as a neighbor just had a Mooney seat redone and it was $3600 just for one seat.  This neighbor had also bought a Juki machine and said it was hard to sew a straight line.  Months previous, my wife caught me watching upholstery videos and commented that I wasn't going to buy a sewing machine.  Other amateur upholsterers in the past had commented they wouldn't make any one else's seats. The mental gymnastics going through my head had lead me to this path of having someone else do it.   I put down a deposit after deciding on material.  Then we laid out the foam and patterns to make sure it was in order and instructions were clear.  Richard showed me some large RC aircraft that he'd designed and built.  He also had a large bicycle that he'd made.

Richard took me to lunch and then back to the airport.  We chatted some more, he took more photos and he watched me depart.

Initially, on climb out, full power, the turbulence wasn't bad but after starting to level off, it was not pleasant.  I pulled the throttle back to about 2300 RPM.  Ground speed fluctuated from 150 mph to 180 mph.  The AP was doing it's job better than I could at maintaining altitude and heading.

Soon, I started to get cramps in my legs.  I reached down to massage my legs and noticed they were cold to my hands, so turned the heat on a little and that helped some.   Suspect the turbulence and lack of cushion under my thighs were also contributing to lack of circulation.  I drank some water, took some of the homeopathic tablets and suffered a couple more cycles of cramps.  I also recalled that I didn't exactly follow the directions for applying Theraworx.   Lesson learned.

Nearing Class B, air traffic was very busy around the airports.  The rainy weather had many students grounded and now they're trying to get their lessons in and time building back in motion.  I opted to stay further south and skirt the Class D's and B to get back to T67.  

Finally back on the ground, I hobbled around and managed to push the Cozy back in the hangar.  The leading edges were splattered with bugs, probably the worst I've seen in two years.  A hazard of flying over lakes.

This is probably one of my least enjoyable flights ever and if every flight was like this, I'd probably quit flying.  OTOH, this would have been almost a 4 hour drive one way and would convince me that flying is wonderful even when it's bumpy.  I know better weather is coming and will soon have some awesome seats.  Oh....and my wife had sticker shock too.   My daughter nailed the price when mom asked her how much she thought it would be.   She said, "You can't take it with you." and I replied, "That might be soon!"  lol

In four weeks, the patio furniture cushions should be back where I borrowed them from.   Maybe I  should finish the wheel pants?




Saturday, April 20, 2024

Cylinder head wrenches - alternative uses

 Cylinder head wrenches can be handy for torquing hard to reach bolts and nuts.  Using the wrench for the prop flange bolts makes it easier for one person to hold the prop and torque the crank flange nuts.  Getting a torque wrench on sump bolts and nuts may a bit easier than using a swivel and extension.  





Saturday, April 13, 2024

Avidyne IFD alert audio not working & seat foam cushions are ready for the upholsterer.

 I'm not getting alerts from the Avidyne IFD 540 and suspect the alert audio pins aren't connected to the audio panel's unswitched audio input #2.   My audio harness was built by ACS in order to get the warranty on the audio panel.  They did mis-pin one wire but is looking like they didn't pin the alert audio wires from the IFD to the audio panel.  We'll see.


I found this on line that I'll try.   If the audio is connected, I should hear chimes when I change volume.

https://pilotsupport.avidyne.com/kb/article/221-i-am-not-receiving-flta-alerts-on-my-ifd5xx4xx/

If there's no chimes, the audio isn't connected.   Bleh.  That will probably take a good 1/2 day to remedy.

- Update....  The alert audio was not pinned from the IFD to the audio panel.  It's connected now and can be verified by adjusting the alert audio and hearing a chime sound.


I got all the seat cushion foam cut last night.   Forgot to take photos before putting it in the box, so will try to get some for the blog and post them.  -Update - a separate blog entry was started for upholstery.




Tuesday, April 9, 2024

Upholstery in progress!

Seat foam (soft and medium soft remnants) was ordered from Dynamic Systems and arrived yesterday (Monday 4/8) .  I have some medium left over from a friend's project and will use some of that too.

 Remnants are available from Dynamic Systems (Sunmate):  https://www.sunmatecushions.com/

Video on shaping seat foam:

 https://www.youtube.com/live/dxDqKdkmGuk?si=Tg8sgZy9qLBDF_eI

My wife wasn't fond of me buying a sewing machine.  Youtube was feeding me video suggestions from https://www.youtube.com/@oldschoolautoupholstery  and he is located at Livingston TX.  The airport is 00R (Zero Zero Romeo).  Richard said he'd be available after April 14th to work on the seat covers.

Template for the back seat.



Passenger seat foam laid out on the wing.

Variation from plans on the thigh support is to cut a round or rectangular edge to make it easier to slide feet under the panel.
Front seat template. Thigh support is shortened and narrowed some.


Pilot seat foam and headrest pad.

Head rests for passengers will go on the battery cover.

Pilot and Copilot headrests will attach with Velcro or snaps.


Friday, March 29, 2024

2024 Condition Inspection

I'll start a post to edit/add items to that I'd like to complete during the CI:

Upholstery......(contacted a shop.  He wants me do the foam and he'll make the covers.)

Complete wing/strake fairing.  Or not.  Bolus tape doesn't look to bad.  I'd rather fly than sand...

Finish wheel pants.  (They're in primer and have some gaps, but see above.)

Touch up paint - nose door and longeron  have some chips.

Check baffling cracks. (Good)

Replace alternator belt. - Done

Canopy seal improved.

External access to canopy latch.

Landing/Taxi lights.

Heater control moved/improved.  Bowden cable..change to actuator.


Items done:

Moved headset jacks.

Installed TVS diodes on starter solenoid coil and "I" terminal.

Installed 5 Amp charging port to passenger area.

Broke ring gear support attempting to replace ring gear with a broken tooth.

Replace ring gear, install SDS magnets.  Made a jig to drill magnet holes.


Things to check on post maintenance flight:

Dynon Software update/operation.  Maintenance item list.  

Heater operation.  Canopy closed circuit.

Dynon (new) radio operation.  Headsets.

Best power TAS @ 7500' DA.

Alternator operation (new belt).

SDS (carrier replaced)


Post flight check (


short flight due to GPS issue - transponder doesn't transmit position):

Intermittent GPS signal...4 wire connector intermittent.  Removed and hard wired the connection.

Engine start - cranked and gradually opened the throttle.




Tuesday, March 26, 2024

Service Bulletin References for N724CZ

 

Service Bulletins, Service Advisories, Plans Corrections, Special Airworthiness Information Bulletins (SAIB)

Created 3/26/2024    Expect some of these links to change or disappear.  The FAA links in particular.

Andair (fuel selector) https://www.andair.co.uk/about/service-alerts/

ACL ELT https://www.ackavionics.com/technical-library/

Avidyne https://www.avidyne.com/manual-guides/

Dynon   https://dynonavionics.com/support-bulletins.php

Matco (wheels & brakes) https://matcoals.com/technical-support/technical-manuals-and-service-bulletins/

Plain Power https://planepower.aero/aircraft-alternator-support/service-bulletins/

SDS EI/EFI   http://www.sdsefi.com/sb.htm

SKy-tec https://skytec.aero/aircraft-starter-support/service-bulletins/

Titan (PMA & Experimental Service Bulletins)  https://continental.aero/pma-service-bulletins/

Vertical Power (VP-X)  https://verticalpower.com/index.php 


Miscellaneous Cozy related Bulletins and advisories at:

http://www.cozybuilders.org/

http://www.cozybuilders.org/Canard_Pusher/

http://www.cozybuilders.org/newsletters/ (plans corrections)

Various items have been discussed in this group (access may be restricted): https://groups.google.com/g/cozy_builders


Misc:

Breaker Switches SAIB (posting a non-FAA link because they move documents and break links).  https://www.aero-news.net/index.cfm?do=main.textpost&id=6a6f4b28-82cc-4fd4-8337-c240470fd3d0

SAIB - Federal Aviation Administration Special Airworthiness Information Bulletins   https://www.faa.gov/aircraft/safety/alerts/saib

ADs  -  FAA DRS (search for Airworthy Directives) https://drs.faa.gov/browse/SAIB/doctypeDetails

ADs (Biweekly (select Small Aircraft) https://drs.faa.gov/reports/ad-biweekly

NTSB ntsb.gov


Monday, March 4, 2024

Dynon SV-COM-425 RMA

My last flight, got a good radio check at the run up area but after taking off, got a reply that my transmit audio had become "weak and scratchy".    I pulled the module, opened it up but didn't see any physical damage.  The pins/sockets of the 25 pin connector looked okay.   The nut holding the antenna connector to the case wasn't very tight, but the threads were plastic so apparently the bulkhead connector's case wasn't a functional ground.

I'd opened a case with Dynon and got an RMA for the radio.   I'm not certain which model I'll get back but will probably have to repin the 25 pin connector.  Shipped priority express, two day.  

Dynon also announced a software update.  Unless told otherwise, I'll wait until the replacement radio is ready to install before upgrading the software.


Update - Dynon appears to be sending a SV-COM-760 and adapter cable.


Saturday, February 17, 2024

More rides

 Doug Steen and Bill James are the newest names on the list of pilot/ATPs that have flown N724CZ.  

Doug contacted me and offered to trade rides.  A neighbor of his needed a ride to retrieve his Bonanza so on a frosty Tuesday morning 2/13/2024 I flew from T67 to 50F (~9 minute flight).

Doug gave us (Bill came along too) a ride in his PA46 JetProp to Georgetown and back to Bourland 50F going up to FL19.  Doug's wife Valerie and son looked over the Cozy.  They showed me their Whitman Tailwind.   An RV in their shop was getting a new Dynon panel.  Doug & Valerie own and operate a 145 repair station for avionics, www.semiplane.com. A podcast interview with Doug: https://open.spotify.com/episode/20oomjCjaZn64kLKr3oqsp?si=jrCzrItfSuiR_j_yEdzUrA

Doug was impressed with stability at low speed.  We had the IAS under 60 KIAS and could bank left or right.  VSI was showing about 600 FPM decent.  

After we got back to 50F we chatted and went to lunch.  When we got back to 50F, Bill was eager to go for a ride.  He asked me about the feeling of the realization that "you built this and are flying it".  I think every time I preflight and push it out of the hangar I'm still getting butterflies.  When we got back to Bourland, we chatted for awhile.  The sun getting lower in the West was my queue to head home.  

 


 

Thursday, February 8, 2024

Trip to KLAW Lawton

Tallying up hours for insurance renewal and FAA survey, I was looking at my own data and was surprised that my logs showed giving 20 different people rides during the last 12 months. The youngest was 9, the oldest was +75. 15 are pilots, at least five are ATP's (two retired).  Three +500 mile trips and one short flight were with 3 on board.

Today was a good day to not give a ride since there was a turbulence SIGMET up higher and wind (per KLAW Lawton OK tower) was 250@18G27 across RWY 17 (150' wide). The Sheppard MOA above me had a few targets on ADS-B, one coming right at me but 1500 feet higher. The METAR wasn't showing as much wind as the tower reported. Despite carrying 85 knots on final, the wind gusts picked up the right wing a couple of times and there were a few moments of excitement after touching down.

Karl Riley & his wife met me at the FBO where he was bestowed Eureka canard core foam.  Karl insisted on paying for some fuel.  I had the lineman put the fuel in the right (upwind) tank. We chatted a bit, watching the wind socks sticking straight out and the linemen were taking photos of the Cozy.  Major construction on a new terminal was going on next door.

I taxied for take off and asked the tower to repeat the wind again.  Gusting 28 at almost 90 degrees.  The guy in the Tower seemed to be using his Dad voice.  Angling into the wind on the 150' wide runway, the rudders were starting to do their job at about 40 knots at about the time I was intersecting the center line.  On departure, the AP wasn't wanting to track very well until the wind direction was more stable at 5500'. The Tower reminded me to use caution exiting Class D and transiting under the MOA ahead.

Radio chatter from a few students when approaching T67 had students making pattern calls for RWY 14.  There was a batch of helos flying patterns at 4T2 (Copeland), so I followed Hwy 287 at 1500' to stay clear of them, KAFW Alliance and KFTW Meacham traffic.  On upwind for 14, the windsocks were showing a comparatively meager crosswind.  A student and instructor along the taxiway had their cameras out as I touched down. Glad I didn't repeat the previous landing and become Internet famous.

One of the FAA survey questions had tickled my memory about a puzzling stat I recalled from my earlier student pilot/CAP days.  Pilots that file flight plans have a lower accident rate.  Today I'd easily filed and activated flight plans for two "short for a Cozy" flights using the EFB on my phone.  Hey...if it helps...why not?  There's still a lot of nothing for miles in parts of OK and TX.  



Saturday, February 3, 2024

Headset jack relocation

 Initially, I installed the headset jacks at the suggested location in the copilot's headrest.


Several issues with this location is that the canopy's pneumatic cylinder is very close to the headset plugs.  Mine was so close to the top set of jacks that the canopy had to be  opened to unplug one of the chords.   Another issue is that the ANR and other headsets have dongles about a foot from the plugs and hang down behind you or could rest on the back rest but still inconvenient to rich in flight with two fair sized adults in the front seat.

I like the ability for the pilot to easily access any of the four headsets jacks while in flight after having some com issues in flight in a rental aircraft.   If you leave a passenger headset plugged in, you could retrieve the headset by grabbing the chord and pulling it from the back seat to the front.

After nearly two hundred hours in the Cozy now, I've decided to move the headset jacks closer to very easy to reach locations for each occupant.   The front jacks will be moved just outboard the control sticks on each side.   The rear passengers will be able to reach theirs while belted in.    The headset dongles will be easy and more convenient to reach.  

The PSEngineering audio panel provides an easy way to isolate passenger audio if necessary.  Carrying a spare headset in the strake mitigates needing to retrieve a headset from the back seat.

The old headset jack panel may serve a new purpose for O2 canula connections to eliminate some of the tube chaos.

Somewhat related is that occasionally I get reports my transmitted audio is low and scratchy.   I checked with a field strength meter and seems both radios are putting out plenty of power.   The Dynon mic sensitivity probably needs tweaked and I need to get better at positioning the mic closer to my mouth.

Update - the SV-COM-425 was replaced with an SV-COM-760.

Wednesday, January 31, 2024

Canard stick time/nose tire low pressure

I gave a fellow some stick time so he would be closer to getting insurance.   He did pretty well and noted that the Cozy was much faster than his older GA aircraft.  We did standard maneuvers and some touch and goes and got fuel at Graham.  

When we got back to Hicks, I checked the front tire pressure and found it was at 10 psi.  so aired it up to 45 and also checked the mains.   One of the valve core filter stems "filters" got stuck in the valve stem so I drilled the plastic out and put in a short valve stem.   

Wednesday, January 24, 2024

Minor maintenance - Alternator whine in GoPro audio

 Previously I'd installed a 470 uF cap across the essential buss but still have some alternator whine on the GoPro audio when playing back audio.   I installed a .47 uF mylar capacitor across the main alternator's output and ground to filter the AC ripple out.  The pitch trim motor also creates some noise but isn't terrible.  I'll see if the .47 uF cap resolves the whine and motor noise.  Also need to check whether the whine is worse using Com 1 or 2.  

Dynon database and charts were updated.  Connector screws were checked.  The copilot side display screws were a tiny bit loose but the connector was pretty secure.  I reseated the displays ethernet connectors and Wi-Fi dongles.  

I installed some more ferrite beads on unshielded nose gear wires that were close to the transponder antenna.

The fuel filter screen was cleaned and reinstalled.

Update - The GoPro audio alternator whine level seems improved.  It seems to make a difference which platform (Windows/iPad/iPhone/Linux) you watch it on and also how  high the volume is.  The noise is less raspy/buzzy than it used to be.

 

Tuesday, January 23, 2024

EZnoselift installation

 Marc Zeitlin's clamp modification to the EZNoselift should eliminate bolts unscrewing and or bending.  It was not hard to install.





Friday, January 19, 2024

Oil samples for 2023 looking good.

 I'd taken oil samples at each oil change (4) since changing from break in oil to XC20-50.  

The lab reports:

MICHAEL: Our thumbs are still up for the 12/06/23 sample. Metals pretty much stayed the same after the

longer oil run, leaving us with no concerns about how this engine's oil-sharing parts are getting along at

136.6 hours. Lead's higher level is just due to the longer oil run --it's from blow-by and it wasn't excessive

for the run. Dirt, water, and fuel stayed out, and insolubles remained low. Nice results all around!



Thursday, January 18, 2024

Cozy builder visit David Desosa

 David has been building a unique Cozy.  Apparently it was a Cozy III morphing into a Cozy IV, one of the first prototypes.   I invited him out so he could go for a ride and take a close look to see if anything I did could help him with build decisions.

We departed T67, went past Stevenville, then North to Graham for 10 gallons of fuel.  About 20 miles West of Hicks, dialed up the radio to see what runway was in use and it was quiet.  Then I radioed we were over the lake and now there was a Cessna taking off staying in the pattern, another student about 8 miles out and two Christen Eagles a ways to the North.  I fell in behind the Cessna in the pattern, the Eagles did a 360 for spacing and I think another aircraft said he was the only aircraft in the pattern.  I called that I was 1 mile final behind the student Cessna and the Christen Eagle said my audio was low.  The targets on the screen when clearing the runway showed three or four aircraft on final and a couple more out west.  Wow!  Busy!  As I was taxiing the Eagle called, "GOOD JOB EVERYBODY!"

Back in the hangar, I pulled the cowl and a screw dropped out of the bottom.  The #2 valve cover was missing one so that mystery was solved quickly. 

A few things popped up on this flight.  The ARINC module went off line, the standby network went unavailable and the fuel pressure glitched to 75 lbs. a couple of times.   The EFIS data was uploaded and will be analyzed for clues.   

I have some 15 volt TVS diodes & some capacitors ordered.  I'll install a small mylar cap across the pitch trim servo since it has generated a bit of noise on the GoPro audio.

The heater control is located where the fuel valve is usually located and is a pain to get to.  I'd like to move it to the side or instrument panel.  An alternative is to implement a servo.

The Telex headset I've used for passengers seems to not get my transmit audio when talking on the radio.  I'd suspected it was in mono mode but checked the dip switches and seems like its set for stereo now.  When we took off, we had some scratchy audio that was cleared by reseating the headset plugs.  

So the squawk list has: ARINC module/standby network alerts.  Noisy headset audio/jacks.  No pilot transmit audio to the copilot.  Move heater control.  Replace missing valve cover screw.  Check the fuel filter, pumps and regulator.  Check connections on the copilot HDX panel.

An email from Marc Zeitlin advises the nose gear clamps have been shipped.  Tracking info shows it will be here tomorrow.

Sunday, January 14, 2024

Starter damage, ring gear and broken teeth.

 Gremlins of a particular species like to break off ring gear teeth and kill starters.

Improper clearance between the starter and ring gear.  This is attributed to a known issue with new Superior ring gears and the Skytec 149NL starters having zero clearance. Destroys starters.

Flipped trigger wire on an EI coil.  This caused the wasted spark to occur on the bottom of the intake stroke causing a kick back.

Starting the engine without sufficient fuel pressure/momentarily bumping the starter switch.

Timing not retarding or advanced when starting and light weight props.

Only missing one tooth this time.


The first issue was resolved by replacing the starter.  Oddly, the issue didn't seem to occur until after several initial engine test runs.  I'd started the engine, was wearing a non-ANR headset and could hear a clattering ring ring sound.  I shut the engine down and quickly found the starter had not disengaged.  It shelled a bearing.  Although it had only been used a few times, it was out of a two year warranty.   A call to tech support at Skytec quickly diagnosed the issue was due to the dimensions that Superior and Skytec used to make these components resulted in no clearance between the gears.  A shim would be required to increase the clearance so that the starter would disengage properly.  

Aeroperformance aka Aircraft Spruce near me had starters in stock so I ordered one.  The price had gone up considerably since I'd purchased one several years ago  There is also a refundable core charge that is dependent on Skytec inspecting the core.  

I made a pattern from the starter's mating surface and fabricated a .020" thick shim out of 2024T3.  The starter was mounted and clearance checked based on instructions from some hot rod web sites.   The starter then disengaged properly after that.  

Shim for starter

So, back to first engine runs... The engine would start fine but then one day when starting....a nasty crunch & kickback sound indicated there were still gremlins.  Ultimately, this cause was attributed to one of the EI coil trigger wires being transposed causing a spark at the bottom of the intake stroke.  

All was well for months, but then one day when for some reason (distraction), I'd neglected to turn on the fuel pump(s) and I'd usually also been able to start the engine by just bumping the starter switch. This is my theory, but apparently when the fuel pressure is low and the injectors fire, only a minuscule amount of fuel enters the intake and if the cylinder that's on the bottom of the its stroke, finally accumulates enough fuel to fire, the engine kicks back.   Since that episode I ensure the fuel pumps are operational before starting and I keep the starter engaged until the engine cranks up.  It is odd that the shear pin in the starter didn't let go before breaking a teeth off the ring gear.  Fortunately others with the same EI/EFI and similar engines haven't had this problem.

The flywheel and ring gear have to pulled off the engine.  I asked some local pros if they'd done this before but no luck.  Searching the interwebs for replacing automotive ring gears found several methods.  One was to heat the ring gear with a hot torch to expand it and it would either fall off or with a few pops with a hammer, come off.  I tried this initially but after paint started blackening decide to try the cold chisel method.  Since this method breaks the ring gear, it made sense to help it out by cutting a slice as deep as possible without damaging the surface under the ring gear.  There is a lip that the ring gear is against so a round cut off wheel can only go so deep, but weaken the gear.  The assembly needs a very solid surface so that the chisel strikes are effective.  Place the ring gear retaining lip up so that the ring gear is driven away from it when it is struck from above. The chisel head is placed in the slot that was cut. A 3 lb. hammer, large cold chisel, gloves and eye protection are prudent.  I tried multiple light strikes initially but didn't make any progress.  Experience revealed on the last two ring gears, that it took three solid whacks to break and depart the ring gear. The ring usually moves a little on the first whack, more on the 2nd and breaks on the third. It comes off faster than a scared cat so heavy gloves are needed to protect your hands.  

Cold chisel and slit cut in the ring gear.
  
3 whacks later.


Installing the new gear is easy.  It's important to verify the tooth count is the same.  The U shaped teeth are on the 149 count gears and V shaped are on the 122 count gears.  The ring gears teeth are machined so it's important to mount the gear with the machined side towards the starter oriented away from the retaining lip.  Make sure all of the mating surfaces are clean and free of burs.  Heat the new gear (oven works fine) to 375 - 400F.  Put the other part in the freezer.  When you're ready...and wear gloves to handle the hot ring,  drop the ring gear on.  It is so loose it spins around but in less than a minute, it will have shrunk and secured itself.



The ring gear will fit in a countertop oven.


Fortunately I haven't had any issues for awhile but will keep watch for those gremlins.




Monday, January 1, 2024

Formation flying practice


Three of us met at KRPH Graham Texas to do some formation practice.  We briefed, flew for an hour and then debriefed.  Mark Richardson got some nice photos and videos.