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Date: Tue, 27 Jun 2006 21:30:41 -0600
From: Bob White <rlwhite@comcast.net>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Time marches on...parts get made
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On Tue, 27 Jun 2006 21:37:52 -0400
Ernest Christley <echristley@nc.rr.com> wrote:

> There hasn't been many building reports lately.  I think everyone is=20
> flying except me.  Anyway, here is some progress I'm making.
>=20
> The oil cooler inlet duct is made as close to what K&W prescribes as I=20
> could get it.  I tested it today with a borrowed static pressure air=20
> meter and a leaf blower.  I couldn't get a steady reading simply holding=
=20
> the probe out in front of the cooler, so I drilled a hole in a spray can=
=20
> cap and poked the probe through  it.  This captured the static pressure=20
> from a representative area and kept the probe tip at a given distance. =20
> The very tip of the cooler measured around 0.39inH20 and the end closest=
=20
> to the tight curve was only 0.25 or so.  But that was only for an inch=20
> or two.  The center read a fairly steady 0.33 across the length, varying=
=20
> =B1.02.  I think I'm going to put this one in the plane.
>=20
> The water cooler is next.  The white tower is the mold I've been making=20
> for the inlet duct.  I laid out the K&W coordinates, and cut them out of=
=20
> doorskin plywood.  Then I slotted them to slip together.  Hot glued a=20
> cap on each end then filled the interior with foam.  Now I'm covering it=
=20
> with lightweight spackling to set the final dimensions.  I should be=20
> ready to do the lay up as soon as it cools off.
>=20
> The final picture is the radiator I'll be using.  12.5x8.5x4.25.  A cap=20
> will cover the factory inlets, and I'll have to mount nipples on both=20
> sides.  There was a baffle on the inlet side that I had to drill=20
> through, but other than that this should be an excellent radiator for=20
> the Delta.  The flow was down the front right, up the back right, over=20
> and then down the left back, then up the left front.  After drilling the=
=20
> baffle and adding my own connectors, the flow will be down the front and=
=20
> up the back.  I was able to slide a piece of clothes hanger that measure=
=20
> .090 into the passage through the hole I drilled.  There are 23 sections=
=20
> with 5 passages in each, for a total area of at least 0.73in2.  My plan=20
> is for 3/4" hose, which only has an area of .44in2 at best.  Flow=20
> through the radiator should not be an issue.  An important point for an=20
> EWP installation.
>=20

Hi Ernest,

I've just finished the fiberglass part of my oil cooler plenum.  I
finished the water cooler plenum a couple of weeks ago.  My plenum's
are far from ideal.  (haven't taken any photos in months, maybe I
should knock the dust off the camera)  The design sort of evolved as I
built so it doesn't look much like I thought it would to start with.
Now you've talked me into doing a leaf blower test! :)  Maybe I can
tell how bad they are before running the engine. =20

I've been whining about fiberglass ever since I started working with
it.  I must be starting to like it though as I'm now finding other
things to make with it.  Yesterday I made a fairly complex cover for
the flap handle which is on the top of the cabin on a BD-4.  I've
already made the form for a rear panel in my rear seat/baggage
compartment area.

Thanks for the update.  It has motivated me to do some more photoing
and testing.  I particularly like your use of cardboard and structural
masking tape.

Bob W.

--=20
http://www.bob-white.com
N93BD - Rotary Powered BD-4 (first engine start 1/7/06)
Custom Cables for your rotary installation -
http://www.roblinphoto.com/shop/