---------------------------------------------------------- Kolb-List Digest Archive --- Total Messages Posted Sun 06/15/14: 8 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 04:26 AM - Re: Rear housing for a Rotax E- gearbox (racerjerry) 2. 07:24 AM - Re: Re: Rear housing for a Rotax E- gearbox (B Young) 3. 07:37 AM - 1/8 inch plug (B Young) 4. 09:50 AM - Tail Wheel Mark IIIC (K I) 5. 03:08 PM - Re: Re: Rear housing for a Rotax E- gearbox (Richard Girard) 6. 05:05 PM - 582 Engine Vibration on Mark III (Kolb List) 7. 06:51 PM - Re: 582 Engine Vibration on Mark III (GARY JINDRA) 8. 07:38 PM - Re: 582 Engine Vibration on Mark III (Malcolm Brubaker) ________________________________ Message 1 _____________________________________ Time: 04:26:32 AM PST US Subject: Kolb-List: Re: Rear housing for a Rotax E- gearbox From: "racerjerry" In order to have a CHANCE to seal, the plug will require a perfectly flat sealing surface exactly perpendicular to the new threads. The sealing washer/gasket is most likely not very forgiving of error. I doubt very much if this job can be performed by hand. The tapping operation and afterward a light skim cut to the sealing surface really needs to be performed with the case clamped securely in a vertical mill like a Bridgeport and most likely needs a Bridgeport with a riser block installed to take the height. -------- Jerry King Read this topic online here: http://forums.matronics.com/viewtopic.php?p=424864#424864 ________________________________ Message 2 _____________________________________ Time: 07:24:45 AM PST US Subject: Re: Kolb-List: Re: Rear housing for a Rotax E- gearbox From: B Young If he uses a 1/8 inch npt pipe thread and plug, it is a tapered thread. No square shoulder necessary. Boyd On Jun 15, 2014 5:28 AM, "racerjerry" wrote: > > In order to have a CHANCE to seal, the plug will require a perfectly flat > sealing surface exactly perpendicular to the new threads. The sealing > washer/gasket is most likely not very forgiving of error. I doubt very much > if this job can be performed by hand. The tapping operation and afterward a > light skim cut to the sealing surface really needs to be performed with the > case clamped securely in a vertical mill like a Bridgeport and most likely > needs a Bridgeport with a riser block installed to take the height. > > -------- > Jerry King > > > Read this topic online here: > > http://forums.matronics.com/viewtopic.php?p=424864#424864 > > ________________________________ Message 3 _____________________________________ Time: 07:37:18 AM PST US Subject: Kolb-List: 1/8 inch plug From: B Young When buying a plug you can go to a plumbing supply and get one work a raised square top, you can get them in steel or brass. I think I would go to a plumber or heating contractor and ask if I could get a used plug from an old gas valve from a water heater or furnace. Most valves have a1/8 inch plug to test manifold pressure, and they have an Allen wrench recess.they would look better. Boyd ________________________________ Message 4 _____________________________________ Time: 09:50:00 AM PST US From: K I Subject: Kolb-List: Tail Wheel Mark IIIC I am working on my recently purchased 1993 Mark III. The tail wheel assemb ly is home-made. It does not track strait as the bushing used by the previo us owner have worn on one side causing the wheel to trail different from th e rudder position. It appears that he used it that way and has worn down on e side of the hard rubber wheel. I know that many Mark III owners have repl aced their original tail wheel assemblies. If any Mark III owners have one laying around the hanger=2C let me know what you need for it. *wrk2win4u@ms n.com* Kurt Sandy=2C UT ________________________________ Message 5 _____________________________________ Time: 03:08:29 PM PST US Subject: Re: Kolb-List: Re: Rear housing for a Rotax E- gearbox From: Richard Girard Boyd, The stock plug is 18 mm (.7087") so you'd have to do a lot of welding to shrink the hole down to a 1/8-27 NPT, for which the tap drill size is only .332". By far the greater problem is keeping that casting from warping and destroying the sealing surface that mates it to the gear case. If that has to be re-cut then you have to spot face all the bearing bores, too, to maintain their clearance. At that point you've probably elevated the cost to the point where it would be cheaper to buy a new gear cover, since no matter what you do you're going to have to re-shim all the bearings to get the proper end plays and bearing pre-loads. When I took the clutch out of my "C" gearbox and put the rubber coupling back in I spent the better part of a day getting it all set up properly and I was fresh out of Lockwood's Rotax school where I'd just done it in class. It's not hard to do but it is quite tedious and should be done in clean room conditions as the clearance tolerances involved are very small and you'll need to find a copy of the two stroke Heavy Maintenance manual to get the procedure. Bottom line if you're out there Denny, I'd call Lockwood and get their estimate on cost to fix. It would be a shame to wreck you're new engine if the gearbox locks up or has a melt down not to mention having to make an emergency off field landing if you're unlucky enough not to be over an airport at the time. My two cents. Rick Girard do not archive PS Denny who was the brilliant mechanic (so called) that did this? I know I'd like to avoid sending him any business. On Sun, Jun 15, 2014 at 9:24 AM, B Young wrote: > If he uses a 1/8 inch npt pipe thread and plug, it is a tapered > thread. No square shoulder necessary. > Boyd > On Jun 15, 2014 5:28 AM, "racerjerry" wrote: > >> >> In order to have a CHANCE to seal, the plug will require a perfectly flat >> sealing surface exactly perpendicular to the new threads. The sealing >> washer/gasket is most likely not very forgiving of error. I doubt very much >> if this job can be performed by hand. The tapping operation and afterward a >> light skim cut to the sealing surface really needs to be performed with the >> case clamped securely in a vertical mill like a Bridgeport and most likely >> needs a Bridgeport with a riser block installed to take the height. >> >> -------- >> Jerry King >> >> >> >> >> Read this topic online here: >> >> http://forums.matronics.com/viewtopic.php?p=424864#424864 >> >> >> >> >> >> >> >> ========== >> " target="_blank">http://www.matronics.com/Navigator?Kolb-List >> ========== >> MS - >> k">http://forums.matronics.com >> ========== >> e - >> -Matt Dralle, List Admin. >> t="_blank">http://www.matronics.com/contribution >> ========== >> >> >> >> * > > > * > > -- Zulu Delta Mk IIIC Thanks, Homer GBYM It isn't necessary to have relatives in Kansas City in order to be unhappy. - Groucho Marx ________________________________ Message 6 _____________________________________ Time: 05:05:46 PM PST US From: "Kolb List" Subject: Kolb-List: 582 Engine Vibration on Mark III Hoping some of you fellow Kolbers have some troubleshooting ideas. One a recent flight, the 582 engine on our Mark III suddenly went from being the usual silky smooth to instant roughness/vibration - almost as if something suddenly broke. We managed to get it back to the home airport about 13 miles away. The whole airframe was shaking, but the engine seemed to be developing full power. Switching from one ignition source to the other had no effect. The engine monitor indicated CHT and EGT to be nearly the same on both cylinders and within the normal range. I've since changed spark plugs, removed both carbs for disassembly, cleaning and inspection. I completely drained the fuel system and put fresh premium alcohol free fuel in. All has had no effect on the vibration. Engine mounts appear to be OK - not broken. The engine develops full power, but still shakes badly. Prop is visually OK. Would appreciate any tips on what to check next. The next step planned is a compression check. Thanks. Gary ________________________________ Message 7 _____________________________________ Time: 06:51:44 PM PST US From: GARY JINDRA Subject: Re: Kolb-List: 582 Engine Vibration on Mark III check torque on prop bolts=0A=0AGary Jindra=0Amark 3 912 ul =0A=0A=0AOn Sun day, June 15, 2014 8:10 PM, Kolb List wrote:=0A =0A =0A=0AHoping some of you fellow Kolbers have some troubleshooting ideas.=C2 - One a recent flight, the 582 engine on our Mark III suddenly went from being the usual silky smooth to instant roughness/vibration =93 almos t as if something suddenly broke.=C2- We managed to get it back to the ho me airport about 13 miles away.=C2- The whole airframe was shaking, but t he engine seemed to be developing full power.=C2- Switching from one igni tion source to the other had no effect.=C2- The engine monitor indicated CHT and EGT to be nearly the same on both cylinders and within the normal r ange.=C2- I=99ve since changed spark plugs, removed both carbs for disassembly, cleaning and inspection.=C2- I completely drained the fuel s ystem and put fresh premium alcohol free fuel in.=C2-=C2- All has had n o effect on the vibration.=C2- Engine mounts appear to be OK - not broken .=C2- The engine develops full power, but still shakes badly.=C2- =C2 -Prop is visually OK.=C2- Would appreciate any tips on what to check next.=C2- The next step planned is a compression check.=C2- Than ==================== ________________________________ Message 8 _____________________________________ Time: 07:38:23 PM PST US From: Malcolm Brubaker Subject: Re: Kolb-List: 582 Engine Vibration on Mark III B gear box? check inspect gear lube for gear wear=C2- C/E gear box check rubber dampener and fly wheel end bolts around starter=0A=0A=C2-=0AMalcol m & Jeanne Brubaker =0AMichigan Sport Pilot Repair =0Ahttp://michigansportp ilotrepair.com=0ALSRM-A, PPC, WS=0AGreat Sails - Sailmaker =0Afor Ultraligh t & Light Sport=0A(989)513-3022=0A=C2-=0A=C2-=0A=C2-=0A=C2-=0A=0A =0A________________________________=0A From: GARY JINDRA =0ATo: "kolb-list@matronics.com" =0ASent: S unday, June 15, 2014 9:51 PM=0ASubject: Re: Kolb-List: 582 Engine Vibration on Mark III=0A =0A=0A=0Acheck torque on prop bolts=0A=C2-=0AGary Jindra =0Amark 3 912 ul=0A=0A=0AOn Sunday, June 15, 2014 8:10 PM, Kolb List wrote:=0A =0A=0A=0AHoping some of you fellow Kolbers have s ome troubleshooting ideas.=C2- One a recent flight, the 582 engine on our Mark III suddenly went from being the usual silky smooth to instant roughn ess/vibration =93 almost as if something suddenly broke.=C2- We man aged to get it back to the home airport about 13 miles away.=C2- The whol e airframe was shaking, but the engine seemed to be developing full power. =C2- Switching from one ignition source to the other had no effect.=C2- The engine monitor indicated CHT and EGT to be nearly the same on both cyl inders and within the normal range.=C2- I=99ve since changed spark plugs, removed both carbs for disassembly, cleaning and inspection.=C2- I completely drained the fuel system and put fresh premium alcohol free fuel in.=C2-=C2- All has had no effect on the vibration.=C2- Engine mount s appear to be OK - not broken.=C2- The engine develops full power, but s till shakes badly.=C2- =C2-Prop is visually OK.=C2- Would appreciate any tips on what to check next.=C2- The next step planned is a compression check.=C2- Than =========== ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message kolb-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Kolb-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/kolb-list Browse Digests http://www.matronics.com/digest/kolb-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.