---------------------------------------------------------- Kolb-List Digest Archive --- Total Messages Posted Tue 06/17/14: 4 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 03:22 AM - Re: Re: Rear housing for a Rotax E- gearbox (Dennis Rowe) 2. 03:08 PM - firefly4Sale (Malcolm Brubaker) 3. 07:00 PM - Re: Kolb-List Digest: 3 Msgs - 06/16/14 (George Bearden) 4. 08:13 PM - Re: 582 Engine Vibration on Mark III (Kolb List) ________________________________ Message 1 _____________________________________ Time: 03:22:42 AM PST US From: Dennis Rowe Subject: Re: Kolb-List: Re: Rear housing for a Rotax E- gearbox Ok all, This is what was done to fix it. The crack was welded, than a 1/4" plate was welded over the old hole. Brough t it home, center drilled and tapped the plate to 1/8 npt. Installed a brass hex head plug which I drilled for safety wire. I'm pretty much done buying used gearboxes. Too many gorillas out there turn ing wrenches on these airplanes. I've had two very bad experiences in the past couple years, one was a used c - box that got lost in the mail due to packaging that didn't allow for the a buse the USPS dishes out, and now I've got this. On the bright side, I ran the 670 yesterday on the stand for ten minutes and it started right up and ran smooth as can be. Very quiet. Of course the set backs included a leak in a weld on the radiator and a leaky outer seal on th e head. New JBM seals are ordered and the rad is at the welder and will get a petcock installed to make draining the coolant a lot less messy. Also inst alling a drain in the water pump housing for the same reason. Dennis "Skid" Rowe Mk3, 690L-70, Leechburg, PA > On Jun 15, 2014, at 6:08 PM, Richard Girard wrote: > > Boyd, The stock plug is 18 mm (.7087") so you'd have to do a lot of weldin g to shrink the hole down to a 1/8-27 NPT, for which the tap drill size is o nly .332". > By far the greater problem is keeping that casting from warping and destro ying the sealing surface that mates it to the gear case. If that has to be r e-cut then you have to spot face all the bearing bores, too, to maintain the ir clearance. At that point you've probably elevated the cost to the point w here it would be cheaper to buy a new gear cover, since no matter what you d o you're going to have to re-shim all the bearings to get the proper end pla ys and bearing pre-loads. When I took the clutch out of my "C" gearbox and p ut the rubber coupling back in I spent the better part of a day getting it a ll set up properly and I was fresh out of Lockwood's Rotax school where I'd j ust 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 v ery 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 est imate on cost to fix. It would be a shame to wreck you're new engine if the g earbox locks up or has a melt down not to mention having to make an emergenc y off field landing if you're unlucky enough not to be over an airport at th e 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 fla t sealing surface exactly perpendicular to the new threads. The sealing was her/gasket is most likely not very forgiving of error. I doubt very much if t his job can be performed by hand. The tapping operation and afterward a ligh t 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 >>> ========== >> >> >> >> get="_blank">http://www.matronics.com/Navigator?Kolb-List >> tp://forums.matronics.com >> _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 > > > 3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3 D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D =3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D 3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3 D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D =3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D 3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3 D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D =3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D 3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3 D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D =3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D > ________________________________ Message 2 _____________________________________ Time: 03:08:34 PM PST US From: Malcolm Brubaker Subject: Kolb-List: firefly4Sale you can check out this slide show and call any time for moor info=0AFor Sal e Kolb Firefly $13,000.00 includes enclosed trailer=0A =0A For Sale Kolb Firefly $13,000.00 includes enclosed trail... =0AView on youtu.be Preview by Yahoo =0A-=0A-=0AMalcolm & Jeanne Brubaker =0AMichigan Sport Pilot Repair =0Ahttp://michigansportpilotrepair.com=0ALSRM-A, PPC, WS=0AGreat Sai ls - Sailmaker =0Afor Ultralight & Light Sport=0A(989)513-3022 ________________________________ Message 3 _____________________________________ Time: 07:00:39 PM PST US From: "George Bearden" Subject: Kolb-List: RE: Kolb-List Digest: 3 Msgs - 06/16/14 Richard Girard, thanks for your many useful posts. I would like to have you reconsider your prolific use of "do not archive". Many, or maybe most of your posts are well worth making available to archive browsing people. GeoB ________________________________ Message 4 _____________________________________ Time: 08:13:07 PM PST US From: "Kolb List" Subject: Kolb-List: RE: 582 Engine Vibration on Mark III Update: Thanks to all who have responded with suggestions on things to inspect. Additional inspection/troubleshooting has still not identified a smoking gun, so I've made an appointment with a nearby Rotax service center later this week to trailer in the whole airplane to their facility and have them take a look at the engine and its installation. Hopefully, this effort will identify the problem. Original Message: 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. 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