nlappos

TJay, yes without cowlings a Jabiru will overheat because it is air cooled and the cowls guide the air over the cooling fins. A Rotax 2 stroke is water cooled, a whole different beast. 

Nope, those are R9, and that is the too-short bolt. I had the same gig on an annual 2 years ago and ordered the R10 from Aircraft Spruce, so the nice to have 2 threads will show. The R9 is 9/16" long the R10 is 5/8". I bought 22 of the AN526-632R10 and became a happy camper.

Serious ground runs today, and I installed the belly radiator that has been on my hangar shelf for 2 years. Yesterday I went to over temp 180 degrees in about 5 to 6 minutes of ground run (OAT 87 degrees, cowlings off). With the belly radiator I ran for 20 minutes today and the temp stabilized after about 12 minutes at 165 or so.
To support the radiator, I used 2 U-Bolts thru the cockpit floor, hooking over the diagonals that go from the center aft to the sidewall. I put the bolt thru the plywood, below the carpet where it didn't interfere at all. I used a cut-away rectangular channel mounted to the U-bolts, and then bolted the radiator to the channel. The channel is about 2" in depth, pulling the radiator down a bit for cleaner air (yes, and more drag). Silicon tubing connected the radiator to the pump output, and the return goes to the right nose radiator.
I set the warp drive to 15 degrees of pitch at the tip, and today ran to full throttle in the chocks, and got 5970 RPM, which is close enough for me to take it to flight. EGT and fuel flow are working fine, so I should get good performance data for the group.High speed taxi tomorrow, if the winds behave.

That is the 670 muffler and exhaust system made by Mike Hair and recommended by Ron Davis (Rotax Rick, who did the engine), it is bigger than the 582. I'll let you know how it works.

Yes, if it were just the engine, I'd agree, but the prop and the gear are also considered 'major changes". I called the FSDO, they said just log the changes, reenter phase 1 for 5 hours, then log the completion with the magic words. No inspection or paperwork.

Progress, finally (spent weeks and weeks on moving, retiring, traveling and such. Finally able to spend time on my MK IV)
Tasks performed in the last few months:
·         Removed Rotax 582 type 99, Hours 191.5 S/N 7626516,                                                                                                

·         Installed Rotax 670 BH18,  engine S/N 4087049, Hours: 0.0

·         Rigged Bing 54 Carbs, new, installed Hacman mixture control, installed 170 Main Jet for 6000 feet

·         Installed 2 EGT sensors into exhaust Y duct, Installed new Facet 2-4 psi fuel pump on left firewall, wired through master switch, separate 5 amp fuse

·         Removed Oil tank, capped off engine tank inlet, bombed off oil mixing input cable from throttle to rt side engine mountOIL MUST BE MIXED IN GAS, 40:1

·         Installed Mike Hair custom 670 exhaust with new reinforced silicone hangers and safety cable, safetied and RTV'd springs

·         Installed new Warp Drive 68" tapered 3-bladed prop with HTL hub, set initial pitch to 15 degrees, torqued all bolts, safetied with lock nuts on inner flange

·         Cut cowling to fit new muffler, reinforced lower edge for strength

·         Removed factory bungee landing gear. Installed Highwing LLC bush gear, rebuilt hubs, lubed bearings, inspected brakes, installed longer brake lines, filled and bled brake system with 5606, checked wheel alignment and angles

·         Removed and installed RT wing, replaced wingtip Whelen strobe/nav lightsm Replaced strut hdwr

·         Replaced Tail Wheel spring with new double spring

·         Installed inspection panel on tail to access TW attach bolt and TW structure

·         Installed new cabin fuel lines and filter fm wing to header tank., Drained fuel system, flushed tanks.

·         Installed new (used) altitude encoder for Xpdr

·         Leveled and weighed aircraft, new weight and CG statement prepared.

·         Completed annual Condition Inspection Items, ready for A&P inspection

·         New engine, landing gear and prop constitute major changes, and require entering Phase I flight test for 5 hours, will make appropriate log entries.


First ground runs yesterday and today, runs like a charm, smooth and sweet! Will report the performance and fuel consumption as I flight test it.
 

Zadwit, how about all the broken tailwheel structure? It looks like it cracked the steel back there to sever the entire TW structure. I suspect your landing was very, very hard. Any idea of the G's on impact?

He couldn't post at first, I suggested Youtube. He did that, which is why we now see it. Nice job, wypaul! I have 2500 hours in Hawks!

wypaul, try putting it up on Youtube.com and just posting the link. Wed love to see it!

Later report and an interview with Jim. He said the engine quit at 150 feet on final, and he landed just short of the runway, clipped a fence and flipped over.
 
http://www.ktuu.com/content/news/Pilot-of-crashed-plane-thanks-Alaskans-for-help-483672651.html

I used the 25 degree wings, which matches the rudder rigging on an Avid. 45 will have difficulty releasing otherwise.

Let's look at the propeller as a wing, and recognize that the wing makes lift (thrust) by a combination of angle of attack (pitch) and airspeed (RPM). f the two, the airspeed is more influential, since the lift equation used the velocity squared.
At 5500 rpm the prop blade tip is moving at 740 feet per second (with a 2.43 reduction box), at 5800 rpm it is at 780 ft/sec. The difference i thrust is about 11%, assuming the engine was producing the same power. But with the engine producing 4 HP more power at 5800, that would make the prop thrust about 15% higher at 5800.

Single ignition.

Fear not, Mark. Because the item induces a dead short, it is actually either positive or negative ground, your choice!

From my experience, Hysol is pretty soluble in MEK, as long as you can keep it away from the other stuff in the area.

Barnstormers has one right now, 24K. I feel like buying it for my wife, as a gift.

Lucas! The Folks who invented darkness.

Radiator cap

Just to report to the group, my 582 Blue Head had 119 psi on each cylinder with 160 hours, and the next year had exactly the same reading (119 psi) with about 80 hours more time. These numbers were recorded with an electric starter.

The HACMAN leans the fuel mixture using the same method as the Rotax approved HAC system (which is illustrated in the Rotax parts manual in the accessories section), except the manual mixture valve. It basically tricks the carb bowl pressure to a lower pressure, making the carb deliver less gasoline to the metering valve (functionally the same as having a smaller main jet). I used a HACMAN on my 582 for 3 years, and it always produced clean plugs and high egts, as I flew from 11000 foot legs in Wyoming to sea level long cruises.
I do think the simple mixing valve and tubing set is not worth $200 and I applaud the guys here who make it cheaper and simpler!

Poor trailer

Progress check: The engine install is complete, with HACMAN installed and cowling cut (and reinforced). Landing gear complete, wings both now spread and bolted, tail reinstalled. Battery and ELT reinstalled.
To Go: Brake lines install, fill and bleed brake system. Electric fuel pump, Warp Drive Prop. Final overall inspection, Ground runs, Fly!
I am frustrated that I have a planned trip that starts Saturday for 2 weeks, so I won't get to fly for a few weeks. Darn.

Thanks! Not yet, Andy. I will use the 90 degree until the 135 arrives, but I have held off installing the spring safeties to last thing. 

Installation essentially complete, here are some shots. I might fly this next week, lots of performance reports to come.

 Making great progress on the overhaul:  The Lowell Fitt (Highwing llc) landing gear is all set to go, mounted the axles and wheels on the new gear (awaiting a new cabane that is long enough to suit the Avid at 32 7/8" wide). 
670 Engine is fully mounted, exhaust fitted, carbs installed, drilled new EGTs, completed and inspected all wiring and plumbing.
Reinstalled the stabilizer and elevator, tailwheel with new spring, and repaired the small dings in the fabric due to 25 years of fun flying.
To go: Re-hang the radiators, install and trim the lower cowl, reinstall the right wing, install the Warp Drive prop. Fully inspect the whole shebang, ground runs and then ----Fly!
Will post some photos in the next few days.