Mailing List flyrotary@lancaironline.net Message #30326
From: John Slade <sladerj@bellsouth.net>
Subject: RE: [FlyRotary] Re: Radio noise saga
Date: Fri, 17 Feb 2006 19:11:22 -0500
To: Rotary motors in aircraft <flyrotary@lancaironline.net>

> I hear The Destroyer of turbos claimed number 3.
Actually, that was #4  

For those interested, here's the "turbo report"

Turbo #1: Stock T03. Used. Not rebuilt.
Overspeed at 46MAP, 11,000'. Turbine wheel departed shaft and stuck in exhaust.
Lesson learned. Stock turbo can't take boost at altitude.

Turbo #2: Stock T03. Used. Not rebuilt.
Similar failure but at lower altitude and boost. A piece of turbo went back into the engine and took out an apex seal. Engine rebuilt. I forget the details, but two's a trend, and this was enough to prove that the stock turbo can't cut it as a permanent solution (but then, they are only $300 used from Rusty)

Turbo #3: T03 Hybrid rebuilt and modified for hi-flow
Bearings failed and dumped oil into intake during runup. Takeoff aborted - insufficient boost and engine running rough.

Turbo #4: Stock T03 Used. Not rebuilt.
Installed while waiting for parts for T04 upgrade. On loan from Bob Tiley for "destructive testing". Mission accomplished. :) I babied the thing. Boost kept below 34 @ 5000'. Lost turbine blade during runup (this afternoon). Misbalanced turbine caused oil release into exhaust and intake. Lots of smoke. Runup aborted.

Turbo #5: Turbonetics T04-P50 - new
Sitting on the bench awaiting install. All parts now in hand. Hope to have it installed next week.

The bottom line here is that I tried to save money and installed used ebay units that weren't rebuilt. $3500 for a new T04 just wasn't available earlier. The prices have come down and a full T04 install with Tial wastegate and XS Power manifold is now around $1500. Three turbos @ 300 each. Engine rebuild = $600 (not including cost of indestructible seals). Hybrid mod = $500. T04 = $1500. Total cost - $3500. Hey! I'm even!

The failure modes are fairly benign. The airplane can fly straight & level with a dead turbo.

I know this is the experimental category, but enough is enough!
John

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