X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from mxo6.broadbandsupport.net ([209.55.3.86] verified) by logan.com (CommuniGate Pro SMTP 5.1c.2) with ESMTP id 1317435 for flyrotary@lancaironline.net; Wed, 26 Jul 2006 18:46:21 -0400 Received-SPF: error receiver=logan.com; client-ip=209.55.3.86; envelope-from=ben@gmpexpress.net Received: from ben22d25bef6f7 (gmp-inet26-11.gmpexpress.net [72.9.26.11]) by mxo6.broadbandsupport.net (Postfix) with SMTP id 6A4C59B6660 for ; Wed, 26 Jul 2006 18:45:23 -0400 (EDT) Message-ID: <000901c6b105$2de9aec0$0b1a0948@ben22d25bef6f7> From: "Ben Baltrusaitis" To: "Rotary motors in aircraft" References: Subject: Re: [FlyRotary] Re: Inconel Date: Wed, 26 Jul 2006 18:45:20 -0400 Organization: Biper Marketing Company MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0006_01C6B0E3.A5157730" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook Express 6.00.2900.2869 X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2900.2869 X-Antivirus: avast! (VPS 0630-2, 07/26/2006), Outbound message X-Antivirus-Status: Clean X-broadbandsupport.net-MailScanner-Information: Please contact the ISP for more information X-broadbandsupport.net-MailScanner: Found to be clean X-broadbandsupport.net-MailScanner-From: ben@gmpexpress.net X-Spam-Status: No This is a multi-part message in MIME format. ------=_NextPart_000_0006_01C6B0E3.A5157730 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Al,=20 That strobe is a great idea! I'm going to do that. I appreciate all the knowledge you share. I'd like to see a pic of your slip fit exhaust. It seems to me I could = use a heavy piece of header pipe that goes all the way into the muffler = and a smaller walled piece for the slip fit with maybe a three inch = overlap. How do you stop the gases from leaking past the slip fit? Thanks! Ben Acroduster Too (still building) 20B ----- Original Message -----=20 From: al p wick=20 To: Rotary motors in aircraft=20 Sent: 07/26/2006 5:56 PM Subject: [FlyRotary] Re: Inconel I have a lot of experience with failure analysis. Used to do it with = GM, Ford, other warranty returns. One of my favorite experiences was = solving a million $ warranty issue on a tubing product. Although I'm not = expert in this area, I'd sure encourage considering other factors, other = solutions. In particular I'd encourage use of strobe lamp. Take cowl off, fire up = engine, use strobe. (yes, it's dangerous with prop on) You will suddenly = have appreciation for the forces involved. You should be able to predict = failure points with this test. Tack together the broken one to see what = I mean.=20 The exhaust will turn into a sine shape at certain rpm. You will see = huge amount of movement on the busted one. Make a new design, compare = movement to predict how long it will last. A very minor design change = can greatly improve how much movement occurs.=20 I'm not sure this is applicable to you guys, but my exhaust design has = slip fit of two pipes instead of welding. It works phenomenal. I've had = conversation with other guys who welded instead and had failures. Same = exact application. So my exhaust floats in relation to the header. I = just attach a small bracket to the floating portion to prevent if from = blowing off. Truthfully, I never expected it to work, but it has quite = well. I might have pic if verbal description not adequate. -al wick Artificial intelligence in cockpit, Cozy IV powered by stock Subaru = 2.5 N9032U 200+ hours on engine/airframe from Portland, Oregon Prop construct, Subaru install, Risk assessment, Glass panel design = info: http://www.maddyhome.com/canardpages/pages/alwick/index.html ------=_NextPart_000_0006_01C6B0E3.A5157730 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
Al, =
That strobe = is a great=20 idea!
I'm going to = do that. I=20 appreciate all the knowledge you share.
I'd like to = see a pic of=20 your slip fit exhaust. It seems to me I could use a heavy piece of = header pipe=20 that goes all the way into the muffler and a smaller walled piece for = the slip=20 fit with maybe a three inch overlap.
How do you = stop the gases=20 from leaking past the slip fit?
Thanks!
Ben
Acroduster = Too (still=20 building)
20B
----- Original Message -----
From:=20 al p = wick
Sent: 07/26/2006 5:56 PM
Subject: [FlyRotary] Re: = Inconel

I have a lot of experience with failure analysis. Used to do it = with GM,=20 Ford, other warranty returns. One of my favorite experiences was = solving a=20 million $ warranty issue on a tubing product. Although I'm not expert = in this=20 area, I'd sure encourage considering other factors, other = solutions.
In particular I'd encourage use of strobe lamp. Take cowl off, = fire up=20 engine, use strobe. (yes, it's dangerous with prop on) You will = suddenly have=20 appreciation for the forces involved. You should be able to predict = failure=20 points with this test. Tack together the broken one to see what I = mean.=20
The exhaust will turn into a sine shape at certain rpm. You will = see huge=20 amount of movement on the busted one. Make a new design, compare = movement to=20 predict how long it will last. A very minor design change can greatly = improve=20 how much movement occurs.
I'm not sure this is applicable to you guys, but my exhaust = design has=20 slip fit of two pipes instead of welding. It works phenomenal. I've = had=20 conversation with other guys who welded instead and had failures. Same = exact=20 application. So my exhaust floats in relation to the header. I just = attach a=20 small bracket to the floating portion to prevent if from blowing off.=20 Truthfully, I never expected it to work, but it has quite well. I = might have=20 pic if verbal description not adequate.
 

-al wick
Artificial intelligence in cockpit, Cozy IV = powered by=20 stock Subaru 2.5
N9032U 200+ hours on engine/airframe from = Portland,=20 Oregon
Prop construct, Subaru install, Risk assessment, Glass panel = design=20 info:
htt= p://www.maddyhome.com/canardpages/pages/alwick/index.html
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