Today's Message Index:
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1. 09:38 AM - Oversized Oil Cooler Installation For IO-390... (Matt Dralle)
2. 09:51 AM - IO-390 Baffle Templates... (Matt Dralle)
Message 1
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| Subject: | Oversized Oil Cooler Installation For IO-390... |
Since the IO-390's a little bigger than the 0-320's and 0-360's traditionally used on the RVs, there have been reports of issues with oil temperatures climbing too high. Marc Ausman has some very interesting findings on his web site http://www.io-390.com regarding his experiences with the IO-390, his RV-7, and some various oil cooler installations he tried. Essentially, it boiled down to using a Steward Warner 10610R oil cooler to keep oil temperatures in a normal range. The problem with the 10610R, however, is that it is a LOT bigger than the stock Van's oil cooler. Mark had trouble fitting it on his RV-7 and I've got even less space on the RV-8.
So, once again, I found myself having the re-engineer to accommodate the IO-390
engine installation. The rear left baffle with the Van's supplied .040" doubler
is sufficiently rigid for the stock oil cooler, but the SW10610R is quite
a bit heavier and also about 1.5 times as wide. Initial fittings looked like
it was going to be a close fit if it would fit at all.
I spent the good part of two full days working on a new design for installing the
SW10610R. I came up with a .063" double that completely shadows the rear baffle
and also ties into the angle on the right of the oil cooler. I emulated
the flow baffles on the stock double by cutting the rear baffle hole slightly
large then bending them back and through the hole in the .063" doubler. I spent
a lot of time carefully measuring and cutting and filing the paired holes
and I'm extremely pleased with the fit and function. I riveted the rear baffle
and the .063" doubler with a matrix of 1/8" rivets at 1" spacing. Probably
went overboard here, but I have to say, it really stiffened up the structure,
so maybe it was worth it.
I orientated the oil cooler such that I was able to catch the mounting screw in
the back of rear cylinder. This will take a huge amount of load off the baffling
components and I'm really glad I noticed that I could use it with just a
little bit of shifting. I also added a 4" long piece of .063" angle cut down
on one side to the center rear baffle picking up the 1/4 mounting screw hole.
This also really tightened up the structure.
I had to file a large half-moon shape out of the right-rear mounting ear on the
oil cooler to clear the engine mount. It is not used structurally on the oil
cooler so no harm done. I opted to use all six mounting screw holes on the oil
cooler instead of the normal four. This also seems to stiffen up the installation.
The oil cooler is sufficiently mounted in toward the centerline such that there
are no clearance issues with the cowling, although there would have been if I
hadn't hogged out such a large half-moon from the oil cooler mount.
The best part of the installation is that the hose fittings are nearly in the stock
location, so I will be able to use the standard hose that come with the FWF
kit. Whew, for once, something works without modification.
All in all, I'm extremely pleased with the oil cooler installation. It is very
solidly mounted, still uses the stock hoses, and clears the cowling.
There are a few more pictures at (Logs 01-11):
http://www.mattsrv8.com/users/display_log.php?user=MattsRV8&project=638&category=2972&log=90253&row=12
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com - Matt's All New RV-8 Construction Blog
Message 2
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| Subject: | IO-390 Baffle Templates... |
Dear Listers,
I have created CAD drawings of the custom baffle pieces I made for the Lycoming
IO-390 installation on my RV-8 project. Other builder's utilizing the Lycoming
IO-390 in their RV-8 or RV-7 should be able to use these templates to greatly
speed up the baffling installation. Note that these templates also include
the cut-down for the top cowling installation. Builders may want to leave the
tops longer than the templates to assure they get a good fit to the cowling.
Attached are the low-res, non-scale JPGs of the templates for reference only.
The high resolution, full-scale PDFs can be downloaded from my RV-8 web site:
http://www.mattsrv8.com/users/display_log.php?user=MattsRV8&project=638&category=2972&log=90450&row=2
The PDFs are meant to be printed 1:1 on 11x17 paper. Be sure to use the reference
dimensions in both the X and Y to verify that your printer is creating scale
diagrams.
Note these pieces worked on my installation, but they may or may not work on others.
No guarantees that they will fit any other installation.
There are many more pictures and descriptions of the installation on my RV-8 website:
http://www.mattsrv8.com/users/category.php?user=MattsRV8&project=638&category=2972
Drop me an email if you decide to use these templates and let me know how they
worked!
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com - Matt's All New RV-8 Construction Blog
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