The Murphy Builders Site

Phil,
I'm running an IO540 and no return line is required.
Al, Moose N526AP
----- Original Message -----
From: "Phil McGrogan" <mcgrogan@air.on.ca>
To: <murphy-rebel@dcsol.com>
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector

(lycoming

part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to

run

a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB

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I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector (lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB





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Hi Phil,

As far as I know, there is no return flow for a Lycoming.

Peter
SR003



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Phil,
They are correct that a return line is not required. That said, on my
Io540-G1D5 instillation I am using a header tank and putting a 1/4 return
line from the throttle body inlet to the header tank. It will have a
restrictor on the line about 1/16 inch drill size. The header tank is then
vented back to the right main tank. The header tank is fed be the tow main
tanks and I located it under the floor on the right side right up t the fire
wall. It also has a drain out the bottom of the airplane for the low point
in the system. The reason I did it is that it allows me to circulate cold
fuel on hot days during starts as well as a last chance for any air or
vapors to "escape" back to the tank. It is extra work, but I think it is
worth it. I basically copied a fuel system from a certified aircraft with
the same engine.
George Coy

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Phil
McGrogan
Sent: Monday, April 28, 2003 8:54 AM
To: murphy-rebel@dcsol.com
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector (lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB





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George,

How big is your header tank (rough dimensions)? Where you describe you placed it (if I understood) there isn't lots of room with rudder peddles and all. In the reading that I have done they suggested a minimum of 2 gallons.

Rick Muller
SR70
-------Original Message-------
From: George Coy <george@gesoco.com>
Sent: 04/28/03 04:24 PM
To: murphy-rebel@dcsol.com
Subject: RE: lycoming I0-540

Phil,

They are correct that a return line is not required. That said, on my
Io540-G1D5 instillation I am using a header tank and putting a 1/4 return
line from the throttle body inlet to the header tank. It will have a
restrictor on the line about 1/16 inch drill size. The header tank is then
vented back to the right main tank. The header tank is fed be the tow main
tanks and I located it under the floor on the right side right up t the
fire
wall. It also has a drain out the bottom of the airplane for the low point
in the system. The reason I did it is that it allows me to circulate cold
fuel on hot days during starts as well as a last chance for any air or
vapors to "escape" back to the tank. It is extra work, but I think it is
worth it. I basically copied a fuel system from a certified aircraft with
the same engine.
George Coy

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Phil
McGrogan
Sent: Monday, April 28, 2003 8:54 AM
To: murphy-rebel@dcsol.com
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil
McGrogan
SR032QB





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Hi George,

Something just struck me; you sell the M14's and you're installing a
Lycoming? Any particular reason that you're not going with a round motor?

Bill Delcambre

----- Original Message -----
From: "George Coy" <george@gesoco.com>
To: <murphy-rebel@dcsol.com>
Sent: Tuesday, April 29, 2003 10:42 AM
Subject: RE: RE: lycoming I0-540

The header tank is 61/4 in wide, 81/2 inch deep(front to back) and 41/4 in
high. This holds about a gallon. The front fittings are bulkhead AN

fittings

that I welded to the tank and simply drilled holes in the firewall and

used

bulkhead nuts to secure the tank. I put some small ears on the bottom and
riveted it to the belly as well. It could be made wider and longer front

to

back. I just folded up some aluminum on hand and welded it up and leak
checked it.
George

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of
rickhm@mindspring.com
Sent: Tuesday, April 29, 2003 12:43 PM
To: murphy-rebel@dcsol.com
Subject: Re: RE: lycoming I0-540

George,

How big is your header tank (rough dimensions)? Where you describe you
placed it (if I understood) there isn't lots of room with rudder peddles

and

all. In the reading that I have done they suggested a minimum of 2

gallons.

Rick Muller
SR70
-------Original Message-------
From: George Coy <george@gesoco.com>
Sent: 04/28/03 04:24 PM
To: murphy-rebel@dcsol.com
Subject: RE: lycoming I0-540

Phil,

They are correct that a return line is not required. That said, on my
Io540-G1D5 instillation I am using a header tank and putting a 1/4 return
line from the throttle body inlet to the header tank. It will have a
restrictor on the line about 1/16 inch drill size. The header tank is then
vented back to the right main tank. The header tank is fed be the tow main
tanks and I located it under the floor on the right side right up t the
fire
wall. It also has a drain out the bottom of the airplane for the low point
in the system. The reason I did it is that it allows me to circulate cold
fuel on hot days during starts as well as a last chance for any air or
vapors to "escape" back to the tank. It is extra work, but I think it is
worth it. I basically copied a fuel system from a certified aircraft with
the same engine.
George Coy

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Phil
McGrogan
Sent: Monday, April 28, 2003 8:54 AM
To: murphy-rebel@dcsol.com
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil
McGrogan
SR032QB

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The header tank is 61/4 in wide, 81/2 inch deep(front to back) and 41/4 in
high. This holds about a gallon. The front fittings are bulkhead AN fittings
that I welded to the tank and simply drilled holes in the firewall and used
bulkhead nuts to secure the tank. I put some small ears on the bottom and
riveted it to the belly as well. It could be made wider and longer front to
back. I just folded up some aluminum on hand and welded it up and leak
checked it.
George

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of
rickhm@mindspring.com
Sent: Tuesday, April 29, 2003 12:43 PM
To: murphy-rebel@dcsol.com
Subject: Re: RE: lycoming I0-540

George,

How big is your header tank (rough dimensions)? Where you describe you
placed it (if I understood) there isn't lots of room with rudder peddles and
all. In the reading that I have done they suggested a minimum of 2 gallons.

Rick Muller
SR70
-------Original Message-------
From: George Coy <george@gesoco.com>
Sent: 04/28/03 04:24 PM
To: murphy-rebel@dcsol.com
Subject: RE: lycoming I0-540

Phil,

They are correct that a return line is not required. That said, on my
Io540-G1D5 instillation I am using a header tank and putting a 1/4 return
line from the throttle body inlet to the header tank. It will have a
restrictor on the line about 1/16 inch drill size. The header tank is then
vented back to the right main tank. The header tank is fed be the tow main
tanks and I located it under the floor on the right side right up t the
fire
wall. It also has a drain out the bottom of the airplane for the low point
in the system. The reason I did it is that it allows me to circulate cold
fuel on hot days during starts as well as a last chance for any air or
vapors to "escape" back to the tank. It is extra work, but I think it is
worth it. I basically copied a fuel system from a certified aircraft with
the same engine.
George Coy

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Phil
McGrogan
Sent: Monday, April 28, 2003 8:54 AM
To: murphy-rebel@dcsol.com
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil
McGrogan
SR032QB





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Well George, ya know, I sorta figured there would be a story coming...
Great reasons, from where I sit. Socialist republic of Vermont, huh? I
once was delivering a Kitfox amphib to New Hampshire. Upon landing for an
overnight in Sussex, New Jersey, I was greeted with "Hi guy, don't know
where you're from but it sure aint New Jersey. State law forbids landing
that thing on any body of water in this state!" Since I had no intention of
doing such, it didn't affect me much, other than thanking the Greater Power
that I didn't live there. Although I have to admit to meeting some of the
friendliest and most generous folks there, that I've ever known.

Bill Delcambre

----- Original Message -----
From: "George Coy" <george@gesoco.com>
To: <murphy-rebel@dcsol.com>
Sent: Tuesday, April 29, 2003 2:29 PM
Subject: RE: RE: lycoming I0-540

Ahhh Bill it is a long story. Basically I bought 35 IAR823 airplanes in
Romania and sold them. I also got a lot of spares. In the spares were 22
IO-540 engines and 24 of the matching Hartzell props.

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Ahhh Bill it is a long story. Basically I bought 35 IAR823 airplanes in
Romania and sold them. I also got a lot of spares. In the spares were 22
IO-540 engines and 24 of the matching Hartzell props. I have sold most of
them. One of the engines I sold had a cam go soft in the first few hours. I
took it back and gave the customer another engine. I overhauled the IO540
and with some judicious trading of some of my other spares (like throttle
bodies, fuel flow dividers, magnetos and fuel pumps) I was able to do a
complete overhaul on the engine for not much money. Lets just say that I am
into an overhauled engine and overhauled prop for less than 1/2 of my cost
for an M14P.
The second part of the story is that I intend to go on amphib floats. I
live in the Socialist Republic of Vermont. We have about 10,000
environmental lawyers who are just waiting for someone to drip 1/2 cupful of
oil on the lake. (lake Champlain). Having flown about 3,000 hrs behind the
M14P engines, I just know that I can not prevent oil on the lake at all
times. I also have a lot of float time and I know how many times I have
misjudged a dock in the wind and had to restart to prevent a disaster or
just plain getting wet. The electric start option would cure that, but at
the decision time we had not developed it yet.

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Bill
Delcambre
Sent: Tuesday, April 29, 2003 12:41 PM
To: murphy-rebel@dcsol.com
Subject: Re: RE: lycoming I0-540

Hi George,

Something just struck me; you sell the M14's and you're installing a
Lycoming? Any particular reason that you're not going with a round motor?

Bill Delcambre

----- Original Message -----
From: "George Coy" <george@gesoco.com>
To: <murphy-rebel@dcsol.com>
Sent: Tuesday, April 29, 2003 10:42 AM
Subject: RE: RE: lycoming I0-540

The header tank is 61/4 in wide, 81/2 inch deep(front to back) and 41/4 in
high. This holds about a gallon. The front fittings are bulkhead AN

fittings

that I welded to the tank and simply drilled holes in the firewall and

used

bulkhead nuts to secure the tank. I put some small ears on the bottom and
riveted it to the belly as well. It could be made wider and longer front

to

back. I just folded up some aluminum on hand and welded it up and leak
checked it.
George

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of
rickhm@mindspring.com
Sent: Tuesday, April 29, 2003 12:43 PM
To: murphy-rebel@dcsol.com
Subject: Re: RE: lycoming I0-540

George,

How big is your header tank (rough dimensions)? Where you describe you
placed it (if I understood) there isn't lots of room with rudder peddles

and

all. In the reading that I have done they suggested a minimum of 2

gallons.

Rick Muller
SR70
-------Original Message-------
From: George Coy <george@gesoco.com>
Sent: 04/28/03 04:24 PM
To: murphy-rebel@dcsol.com
Subject: RE: lycoming I0-540

Phil,

They are correct that a return line is not required. That said, on my
Io540-G1D5 instillation I am using a header tank and putting a 1/4 return
line from the throttle body inlet to the header tank. It will have a
restrictor on the line about 1/16 inch drill size. The header tank is then
vented back to the right main tank. The header tank is fed be the tow main
tanks and I located it under the floor on the right side right up t the
fire
wall. It also has a drain out the bottom of the airplane for the low point
in the system. The reason I did it is that it allows me to circulate cold
fuel on hot days during starts as well as a last chance for any air or
vapors to "escape" back to the tank. It is extra work, but I think it is
worth it. I basically copied a fuel system from a certified aircraft with
the same engine.
George Coy

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com]On Behalf Of Phil
McGrogan
Sent: Monday, April 28, 2003 8:54 AM
To: murphy-rebel@dcsol.com
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil
McGrogan
SR032QB

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Hi George,
Where in VT are you? I'm a born and raised Vermonter from Springfield.
Family farm has been in the family for 138 yrs. They sold off about half of
it 3 yrs ago. I take it your in the north? I also have family that own
propery agacent to Rutland aprt. Sure is nice they way the flatlanders have
decided how to run the enviroment and morals of the Green Mt state. Still
though, I do miss home, even if I have been in Michigan since 1967! Curt
Rebel N97MR



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Hi Phil,

I have the opportunity to purchase a IO-540-G1D5 and matching prop. I would
be
interested in finding out what your experience is with this engine. Please
contact me
off list.

Tim Saxton
SR030
tim.saxton@shaw.ca

----- Original Message -----
From: "Phil McGrogan" <mcgrogan@air.on.ca>
To: <murphy-rebel@dcsol.com>
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB





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Please don't respond off list, I learn from discussions not specific to my
project as well.

Thanks,

John...369R

At 08:38 AM 6/25/2005, you wrote:

Hi Phil,

I have the opportunity to purchase a IO-540-G1D5 and matching prop. I would
be
interested in finding out what your experience is with this engine. Please
contact me
off list.

Tim Saxton
SR030
tim.saxton@shaw.ca

----- Original Message -----
From: "Phil McGrogan" <mcgrogan@air.on.ca>
To: <murphy-rebel@dcsol.com>
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB





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~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Fly too low or too slow and the ground will rise up and smite thee.






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As far as I know, lycoming engines do not require fuel return line to the tank....

Peter K
SR003 Moose
IO-540 K1G5D





Tim Saxton <tim.saxton@shaw.ca> wrote:
Hi Phil,

I have the opportunity to purchase a IO-540-G1D5 and matching prop. I would
be
interested in finding out what your experience is with this engine. Please
contact me
off list.

Tim Saxton
SR030
tim.saxton@shaw.ca

----- Original Message -----
From: "Phil McGrogan"
To:
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in advance
for your time.

Phil McGrogan
SR032QB





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---------------------------------
Yahoo! Sports
Rekindle the Rivalries. Sign up for Fantasy Football



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Phil:
I have the same IO-540 please share with all on the list if you will.
Thanks,
Tom Packard
SR043
----- Original Message -----
From: "Tim Saxton" <tim.saxton@shaw.ca>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 25, 2005 10:38 AM
Subject: Re: lycoming I0-540

Hi Phil,

I have the opportunity to purchase a IO-540-G1D5 and matching prop. I

would

be
interested in finding out what your experience is with this engine. Please
contact me
off list.

Tim Saxton
SR030
tim.saxton@shaw.ca

----- Original Message -----
From: "Phil McGrogan" <mcgrogan@air.on.ca>
To: <murphy-rebel@dcsol.com>
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel injection
system. The reason I am looking for this info is to decide if I need to
run
a return line back to the tank, or if the flow is minimal, I can tee the
return upstream of the gasolator (with a check valve). Thanks in

advance

for your time.

Phil McGrogan
SR032QB

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Hi Tom,

Phil lost his project in a shop fire which is why he hasn't been active on
the list for some time. He was kind enough to reply to me.

Here some of what I've found out about the engine so far. The IO-540's don't
require a header tank or fuel return but it seems that several builders are
still installing. I suppose this is the "belt and suspenders" approach. I'm
inclined to simplify the system and not install, unless someone can point
out definitive advantages of header/fuel return..

The IO-540-G1D5 (290 HP) is similar to the K engines (300 HP) but the G
engines are limited to 2575 RPM and the K engines have the larger
crankshaft. The G1D5 has rear facing air induction which might be a problem
with the Murphy engine mount. I've talked to Raven Aircraft
http://www.ravenaircraft.com/, they can supply an inexpensive modification
to convert to forward facing which is probably the way to go.

I can get a HC-92WK-1D prop with the engine. This is the matching prop for
the engine. It is a 88" 2 blade prop.

I'm planning on sending the engine to Aerosport Power for inspection and
test run. I'll also have the stock alternator and starter replace with light
weight versions. I'm also interested in the E-Mag electronic ignition for
the engine, http://www.emagair.com/. These replace the standard magnetos.
There are two versions, E-MAG and P-MAG. The P-MAG is self powered so you
don't have to worry about an electrical system failure stopping your engine.
They say they are developing a Lycoming 6-cylinder version which will be
available in the fall.

Tim
SR030

----- Original Message -----
From: <jtpackard@usfamily.net>
To: <rebel-builders@dcsol.com>
Sent: Monday, June 27, 2005 6:27 AM
Subject: Re: lycoming I0-540

Phil:
I have the same IO-540 please share with all on the list if you will.
Thanks,
Tom Packard
SR043
----- Original Message -----
From: "Tim Saxton" <tim.saxton@shaw.ca>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 25, 2005 10:38 AM
Subject: Re: lycoming I0-540

Hi Phil,

I have the opportunity to purchase a IO-540-G1D5 and matching prop. I

would

be
interested in finding out what your experience is with this engine.
Please
contact me
off list.

Tim Saxton
SR030
tim.saxton@shaw.ca

----- Original Message -----
From: "Phil McGrogan" <mcgrogan@air.on.ca>
To: <murphy-rebel@dcsol.com>
Sent: Monday, April 28, 2003 5:53 AM
Subject: lycoming I0-540

I am doing the fuel system in my SR3500 and would like to know if any
anyone knows the volume of the return flow from the fuel injector
(lycoming
part #77003). The engine is an IO-540 G1D5 with a bendix fuel
injection
system. The reason I am looking for this info is to decide if I need
to
run
a return line back to the tank, or if the flow is minimal, I can tee
the
return upstream of the gasolator (with a check valve). Thanks in

advance

for your time.

Phil McGrogan
SR032QB

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