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Date: Sun, 8 Feb 2009 20:07:38 -0800
Message-ID: <1ab24f410902082007x474b787fn215ae2ca21a3f236@mail.gmail.com>
Subject: New failure mode
From: Lynn Hanover <lehanover@gmail.com>
To: flyrotary@lancaironline.net
Content-Type: multipart/mixed; boundary=0016364177e1e2de8504627482f4

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*From:* Bill Schertz <wschertz@comcast.net>
*To:* Rotary motors in aircraft <flyrotary@lancaironline.net>
*Sent:* Sunday, February 08, 2009 5:30 PM
*Subject:* [FlyRotary] NEW failure mode for 13B

Well, I haven't heard of this happening before -- I was ground running my
engine to  tune it with the EM-2 and EC-2.  Ran for almost an hour, at
various rpm's to change the manifold pressure and tweak the settings.
Cooling working well, I had the top cowling off to allow good exit area
since I was tied down. Coolant pressure about 14 psi as reported on the
EM-2.

Engine was running good, took it up to ~6000 rpm swinging a 76x76 Catto
prop, when suddenly there was steam and fluid on my windshield. Shut it down
by killing power to the EC-2. Coolant everywhere.

Got out and looked to diagnose the problem -- NOT my plumbing.  A FREEZE
PLUG in the iron housing had blown out. Rapid coolant dump.

Secondary effect -- Since I shut down suddenly from full tilt, either the
proximity of the cowl to the exhaust, or possibly some of the coolant on the
exhaust started a small fire on my cowl. Put it out with extinguisher, but
corner is charred.


Bill Schertz
KIS Cruiser #4045
N343BS
Now in repair mode.

It is not a common thing to have happen in any engines. In Cosworth blocks I
did this mod just because the blocks cost as much as my house. I have seen
one fall out of a rotary, because pure water was left in over a winter. It
was a plug in the front iron and allowed water into the pan. The bearings
were lost and I got a rebuild job out of that one.

When replacing the plug with a new one, wire brush the anodize off of the
sealing sides of the new plug.

With a die grinder just break the outside  corners of the hole. Apply a thin
coat of Non Hardening Permatex
gasket cement to the hole walls and outside of the plug.

Cover the plug with a piece of aluminum. Drive the plug in with a heavy,
slow moving hammer, to just flush.

You might think about adding two or three 8-32 or 10-32 threaded screw holes
around the edge of the hole and install a small washer that covers part of
the plug as shown. Use socket head screws and wire as shown. When you
overhaul an engine replace all of the plugs with new.

Lynn E. Hanover

--0016364177e1e2de7e04627482f2
Content-Type: text/html; charset=ISO-8859-1
Content-Transfer-Encoding: quoted-printable

<div style=3D"BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><b>=
From:</b> <a title=3D"mailto:wschertz@comcast.net" href=3D"mailto:wschertz@=
comcast.net">Bill Schertz</a> </div>
<div style=3D"FONT: 10pt arial"><b>To:</b> <a title=3D"mailto:flyrotary@lan=
caironline.net" href=3D"mailto:flyrotary@lancaironline.net">Rotary motors i=
n aircraft</a> </div>
<div style=3D"FONT: 10pt arial"><b>Sent:</b> Sunday, February 08, 2009 5:30=
 PM</div>
<div style=3D"FONT: 10pt arial"><b>Subject:</b> [FlyRotary] NEW failure mod=
e for 13B</div>
<div><br></div>
<div><font face=3D"Arial" size=3D"2">Well, I haven&#39;t heard of this happ=
ening before -- I was ground running my engine to&nbsp; tune it with the EM=
-2 and EC-2.&nbsp; Ran for almost an hour, at various rpm&#39;s to change t=
he manifold pressure and tweak the settings. Cooling working well, I had th=
e top cowling off to allow good exit area since I was tied down. Coolant pr=
essure about 14 psi as reported on the EM-2.</font></div>

<div><font face=3D"Arial" size=3D"2"></font>&nbsp;</div>
<div><font face=3D"Arial" size=3D"2">Engine was running good, took it up to=
 ~6000 rpm swinging a 76x76 Catto prop, when suddenly there was steam and f=
luid on my windshield. Shut it down by killing power to the EC-2. Coolant e=
verywhere.</font></div>

<div><font face=3D"Arial" size=3D"2"></font>&nbsp;</div>
<div><font face=3D"Arial" size=3D"2">Got out and looked to diagnose the pro=
blem -- NOT my plumbing.&nbsp; A FREEZE PLUG in the iron housing had blown =
out. Rapid coolant dump.</font></div>
<div><font face=3D"Arial" size=3D"2"></font>&nbsp;</div>
<div><font face=3D"Arial" size=3D"2">Secondary effect -- Since I shut down =
suddenly from full tilt, either the proximity of the cowl to the exhaust, o=
r possibly some of the coolant on the exhaust started a small fire on my co=
wl. Put it out with extinguisher, but corner is charred.</font></div>

<div><font face=3D"Arial" size=3D"2"></font>&nbsp;</div>
<div><font face=3D"Arial" size=3D"2"></font>&nbsp;</div>
<div><font face=3D"Arial" size=3D"2">Bill Schertz<br>KIS Cruiser #4045<br>N=
343BS</font></div>
<div><font face=3D"Arial" size=3D"2">Now in repair mode.</font></div>
<div>&nbsp;</div>
<div>It is not a common thing to have happen in any engines. In Cosworth bl=
ocks I did this mod just because the blocks cost as much as my house. I hav=
e seen one fall out of a rotary, because pure water was left in over a wint=
er. It was a plug in the front iron and allowed water into the pan. The bea=
rings were lost and I got a rebuild job out of that one. </div>

<div>&nbsp;</div>
<div>When replacing the plug with a new one, wire brush the anodize off of =
the sealing sides of the new plug. </div>
<div>&nbsp;</div>
<div>With a die grinder just break the outside&nbsp; corners of the hole. A=
pply a thin coat of Non Hardening Permatex</div>
<div>gasket cement to the hole walls and outside of the plug. </div>
<div>&nbsp;</div>
<div>Cover the plug with a piece of aluminum. Drive the plug in with a heav=
y, slow moving hammer, to just flush. </div>
<div>&nbsp;</div>
<div>You might think about adding two or three 8-32 or 10-32 threaded screw=
 holes around the edge of the hole and install a small washer that covers p=
art of the plug as shown. Use socket head screws and wire as shown. When yo=
u overhaul an engine replace all of the plugs with new. </div>

<div>&nbsp;</div>
<div>Lynn E. Hanover</div>
<div>&nbsp;</div>

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