Wednesday, September 17, 2014

Crossed the Line - Final Repair Progress Report


It feels good to have crossed the line.  Very good.

This was my fourth major test flight in this aircraft.  I'm talking about the test flight when you are thinking about the 1,000 details you tended to.  The hundreds of details that can have a significant problematic outcome for the flight. But finally, there comes a time when you say to your self, "Self, there is no reason not to fly". It's ready.

Not to say I wasn't looking for reasons.  For instance, when I got to the airport I realized I had forgotten my wallet, so pilot's certificate and medical were missing from my person. So, I drove back home (only 5 minutes each way) to get it.

I called the control tower on the phone and warned them I was going to attempt to commit aviation again.  They obligingly had the 45 SIU Flight School aircraft stand down. (JK - but for some reason all their aircraft were parked on the ramp.)

I got out to the departure end of 18L and did the run-up.  Crap.  Another fouled plug, but this time I was able to clear it.  Went through the take-off checklist and again, no reason not to fly.  The take off was non-eventful, as we like to say.  Cylinder head temps immediately went into the yellow, but this is expected with an engine that has new everything.  Got to 3,500 feet and leveled off there.

Circled and circled. It wanted to roll a bit to the left, but that is kind of expected, but overall I am pleased how the trim wound up. While I was up there, I did a single stall to see if any if the flight characteristics had changed.  I seemed to get pitch buck at 65 mph, which is great - I think it used to be around 74 mph, but there is plenty more testing and tweaking to do.

Click to read the numbers:

The landing was acceptable.  I wound up coming in hot, I was doing 100 across the numbers, but it slowed down and I didn't bounce the landing.  I have to say, with a careful job of doing the David Gall alignment, it is tracking really well.

Got it back to the hangar and I had that familiar and wonderful sense of relief.

Special Note


Of course, this would have been impossible but for the enormous help from my family and friends.  Impossible.

My thanks, thanks, thanks to all who were so kind as to contribute towards the effort. I'm sure I have inadvertently left out a name or two, for that I apologize. In fairly random order:

Sandy Hoskins
Pat McGuire
Bill Hunter
Dan Yeager
Craig Catto (propeller sponsor)
Charley Rodriguez
Sport Air Racing League
Larry Flesner
Clarke Deacon
Quickie Builders Association
Nathan Peck
Vic Vacari
Randy Bateman
EAA Chapter 277
Bob Malechek
Sanjay Dhall
EAA AirVenture Cup Race
Jerry Marstall
Bob Kolkmeyer
Pete Polete
SIU Aviation Technologies
Mike Burgener
Rob Hoskins
Gary Hertzler
David Gall






Post Script.  It turned out the significant oil leak was mainly due to a cracked oil screen housing. I am glad we did the work on the sump, but most of the oil was from the housing.  Fortunately, I was able to locate a new one on EBay for $26.  Continental Motors probably would have wanted $400.



Not sure, but the oil leaks probably took three weeks to resolve and that's the way it goes.



Friday, September 05, 2014

Going after the oil leak

So I'm working on my leaking custom oil sump.

A few year back, I replaced the original steel sump with this aluminium one to make the bottom of the cowl more streamlined. You can read a bit about it here: http://samhoskins.blogspot.com/2010/05/so-whats-deal-sam.html and here: http://samhoskins.blogspot.com/2010/05/new-oil-sump-engine-start.html

Oil leaks are hard to detect. I was pretty certain I had a crack on the flat aft edge of the sump. I got hold of a dye penetrant kit and it told me a different story.  What I thought was a crack was only a scratch. The main culprit was a crack in a weld next to the filler spout, in the right side of the photo. (The big red blobs in the middle are from not being able to remove the excess penetrant under the support gussets).



I took the tank to a local talented welder to fix it up. He is going to have to hang on to it for a few days, so no aviating until then.