Jimmy,
Some time ago, the factory went to another exhaust manufacturer CKT Aero
engineering and they did a good job of remanufacturing our exhaust with
thicker, better stainless steel, better muffler supports and less stress
on the mandrel bends of the pipes. CKT also makes systems for most of
the Rotax powered kits in Europe. Too bad we all had the older exhaust
sold to us before which cracked at the exhaust, pipes and everywhere for
mostly harmonic reasons . The only problem with the CKT exhaust was the
springs, which were standard motorcycle carbon steel type, now he makes
a stainless steel spring to try to get better longevity. CKT stands
behind their products and has taken care of me.
Note: In certified aircraft we put RTV or high temp red silicone on the
springs to reduce vibration harmonics. I run a piece of safety wire
through the spring and pull it up loosely. This keeps any fatigued
springs from becoming FOD.
Some History:
The 912S harmonics cause the exhaust to move laterally a bit and that
will fatigue crack in the bend of the exhaust of any system and if the
springs were made tighter, the muffler supports cracked. We all know
how bad the aluminum heat shield was. Also the 914 had some real
problems but over time, metal bends went to welded seams and we have
been trouble free. The original 912 exhaust was kept as light as
possible, but the vibration and harmonics caused fatigue cracks at very
low time. My first experience was with Ira Rampil's exhaust which
cracked in about 4 places. Chris at CKT replaced the old exhaust with
his and we went through some teething pains with it but not too bad
except for spring failures on the right side of the engine. Contact
Europa for the new exhaust system and clear up your problems, but expect
it to cost about $1000 US or about 660 UK Pounds.
Bud
----- Original Message -----
From: James Kelly<mailto:europajimkelly@gmail.com>
To: europa-list@matronics.com<mailto:europa-list@matronics.com>
Sent: Saturday, August 10, 2013 6:07 PM
Subject: Re: Europa-List: Gusset plates
Hi Bud,
It appears that there's always problems with Europa
exhaust pipes cracking near the manifold, any ideas why this is so
prevalent ?
Jimmy
On Sat, Aug 10, 2013 at 9:34 PM, Bud Yerly
<budyerly@msn.com<mailto:budyerly@msn.com>> wrote:
Tony,
If you have a gap but the plate is parallel or close to parallel to
the tube you can put a small joggle in the steel. However then your
bolt hole to edge distance becomes critical on the wood glass gusset.
If there is still good edge distance you'll be OK.
Another method is to put a filler strip to take up the gap of steel.
Just a short strip with a couple holes in it match drilled will do.
It should only add a bit of time and be more than secure.
All one is looking for is to keep the tube stable.
Best Regards,
Bud Yerly
----- Original Message -----
From: Tony Renshaw<mailto:tonyrenshaw268@gmail.com>
To: europa-list@matronics.com<mailto:europa-list@matronics.com>
Sent: Saturday, August 10, 2013 2:00 AM
Subject: Europa-List: Gusset plates
<tonyrenshaw268@gmail.com<mailto:tonyrenshaw268@gmail.com>>
Gidday,
I am having trouble with the gusset plates. I used the 12 ply
supplied and shaped it accordingly, except I have about a 5 mm gap from
ply to tie rod. The cloth will take up approx half of that. So, I bonded
on the ply and then layed up the 4 plies of BID, which in essence
thickens the ply by 8 plies. So, now that its all done I have a 2-3 mm
gap +/- and the gusset plates do not sit parallel. For the other side I
lightly clamped the plates together as the BID cured, in situ, and they
were covered in Canauba Wax for a release agent. So, that side is OK,
but the first side I have a problem I am hoping I can use Redux and Flox
to pack out both the gap between rod and ply, and also to create a flat
bed for the gusset plates. I am wondering this would be considered an
acceptable way to fix things? I know Redux and Flox is a pretty tough
mix and the loads in this region I do not consider will challenge what I
am doing, as something would have already broken, like a wing!
Regards
Tony p; Features Chat, http://www.matronnbsp; via the
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