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Cooling Plenum, Was: Re: Importance of good baffle seal

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David Ricker

Cooling Plenum, Was: Re: Importance of good baffle seal

Post by David Ricker » Sat Feb 18, 2012 9:26 am

Wayne you have brought to mind someting have been contemplating for a while and
that is building a proper sealed plenum for the cooling air.

I have seen a couple of pictures in the mags. that show something like this
where a complete box is formed around the engine in a way that mimics the baffle
enclosure but since it is assembled before the cowl top is put on you can be
sure that there are no uncontrolled air leaks. Of course you have to attach
flexible ducts from the cowl intakes to the plenum but that can be done.

What do you guys think of the idea? Given Wayne's story it sounds like a good
way to design out the doubts & problems of fitting & trimming baffle rubbers and
wondering if that is why the engine runs hot.

The units I have seen were fibreglass and I believe blow molded in polyethelyne,
of course blow mold tooling would be pricy......

Anyway, just wanted to toss the idea around & see what you think.

Dave

"Wayne G. O'Shea" wrote:
FYI for those guys complaining of high CHT's you might want to have a good
look. Have a local guy here with an O-320 in a Luscombe that has been
removed and shoved engine back up the overhaulers @$$ 3 or 4 times in the
last year and a half.... telling him he did a shit job on the overhaul. Case
has made trips to ECI, cylinders have been redone twice etc and still
running high. One of our chapter members said to him last week.."you really
should take that ratty baffle seal off and put some new stuff on...it sure
might help". When he finally gave in and listened the CHT's dropped ONE
HUNDRED!!! degrees F! Makes you wonder if any of the nine or ten thousand
dollars in extra work and a year of aircraft downtime (and the fun of
pulling a motor on and off using a tripod on the beach!!) and tinkering
actually did anything.

Cheers,
Wayne

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David A. Ricker
Fall River, Nova Scotia
Canada






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Bob Patterson

Cooling Plenum, Was: Re: Importance of good baffle seal

Post by Bob Patterson » Sat Feb 18, 2012 9:26 am

Hi Dave !

A pre-formed plenum is a good idea - Rotax has been supplying
these for the 912's for years ! They had to - Diamond was cooking engines
in their too-tight cowlings, so Rotax designed the plenums to ensure
cooling air ....

I believe there are manufacturers supplying plenums for Lycomings
too - let us know if you find one. Sure would simplify cowling
installations !

.......bobp

-------------------------------orig.-------------------------
On Thursday 26 August 2004 11:12 pm, David Ricker wrote:
Wayne you have brought to mind someting have been contemplating for a
while and that is building a proper sealed plenum for the cooling air.

I have seen a couple of pictures in the mags. that show something like this
where a complete box is formed around the engine in a way that mimics the
baffle enclosure but since it is assembled before the cowl top is put on
you can be sure that there are no uncontrolled air leaks. Of course you
have to attach flexible ducts from the cowl intakes to the plenum but that
can be done.

What do you guys think of the idea? Given Wayne's story it sounds like a
good way to design out the doubts & problems of fitting & trimming baffle
rubbers and wondering if that is why the engine runs hot.

The units I have seen were fibreglass and I believe blow molded in
polyethelyne, of course blow mold tooling would be pricy......

Anyway, just wanted to toss the idea around & see what you think.

Dave

"Wayne G. O'Shea" wrote:
FYI for those guys complaining of high CHT's you might want to have a
good look. Have a local guy here with an O-320 in a Luscombe that has
been removed and shoved engine back up the overhaulers @$$ 3 or 4 times
in the last year and a half.... telling him he did a shit job on the
overhaul. Case has made trips to ECI, cylinders have been redone twice
etc and still running high. One of our chapter members said to him last
week.."you really should take that ratty baffle seal off and put some new
stuff on...it sure might help". When he finally gave in and listened the
CHT's dropped ONE HUNDRED!!! degrees F! Makes you wonder if any of the
nine or ten thousand dollars in extra work and a year of aircraft
downtime (and the fun of pulling a motor on and off using a tripod on the
beach!!) and tinkering actually did anything.

Cheers,
Wayne

-----------------------------------------------------
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List administrator: mike.davis@dcsol.com
-----------------------------------------------------
--
David A. Ricker
Fall River, Nova Scotia
Canada






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David Ricker

Cooling Plenum, Was: Re: Importance of good baffle seal

Post by David Ricker » Sat Feb 18, 2012 9:26 am

Pre-builts for Lycs eh? Never heard of that but it is interesting. I figured it
would be a job for the trusty solid modeler (3D CAD).

Dave

Bob Patterson wrote:
Hi Dave !

A pre-formed plenum is a good idea - Rotax has been supplying
these for the 912's for years ! They had to - Diamond was cooking engines
in their too-tight cowlings, so Rotax designed the plenums to ensure
cooling air ....

I believe there are manufacturers supplying plenums for Lycomings
too - let us know if you find one. Sure would simplify cowling
installations !

.......bobp

-------------------------------orig.-------------------------
On Thursday 26 August 2004 11:12 pm, David Ricker wrote:
Wayne you have brought to mind someting have been contemplating for a
while and that is building a proper sealed plenum for the cooling air.

I have seen a couple of pictures in the mags. that show something like this
where a complete box is formed around the engine in a way that mimics the
baffle enclosure but since it is assembled before the cowl top is put on
you can be sure that there are no uncontrolled air leaks. Of course you
have to attach flexible ducts from the cowl intakes to the plenum but that
can be done.

What do you guys think of the idea? Given Wayne's story it sounds like a
good way to design out the doubts & problems of fitting & trimming baffle
rubbers and wondering if that is why the engine runs hot.

The units I have seen were fibreglass and I believe blow molded in
polyethelyne, of course blow mold tooling would be pricy......

Anyway, just wanted to toss the idea around & see what you think.

Dave

"Wayne G. O'Shea" wrote:
FYI for those guys complaining of high CHT's you might want to have a
good look. Have a local guy here with an O-320 in a Luscombe that has
been removed and shoved engine back up the overhaulers @$$ 3 or 4 times
in the last year and a half.... telling him he did a shit job on the
overhaul. Case has made trips to ECI, cylinders have been redone twice
etc and still running high. One of our chapter members said to him last
week.."you really should take that ratty baffle seal off and put some new
stuff on...it sure might help". When he finally gave in and listened the
CHT's dropped ONE HUNDRED!!! degrees F! Makes you wonder if any of the
nine or ten thousand dollars in extra work and a year of aircraft
downtime (and the fun of pulling a motor on and off using a tripod on the
beach!!) and tinkering actually did anything.

Cheers,
Wayne

-----------------------------------------------------
List archives located at:
https://www.dcsol.com/default.htm
username "rebel" password "builder"
Subscription services located at:
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List administrator: mike.davis@dcsol.com
-----------------------------------------------------
--
David A. Ricker
Fall River, Nova Scotia
Canada






-----------------------------------------------------
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List administrator: mike.davis@dcsol.com
-----------------------------------------------------
-----------------------------------------------------
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-----------------------------------------------------
--
David A. Ricker
Fall River, Nova Scotia
Canada






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Rick Harper

Cooling Plenum, Was: Re: Importance of good baffle seal

Post by Rick Harper » Sat Feb 18, 2012 9:27 am

G'day dave & others !

We just put a "sooped up " IO-320 in our Rebel .... puts out 180ish HP
(it's a bit tired)

absolutely NO overtemp problems ANYWHERE ......

why ????


HUGE outlet area on the lower cowl & GOOD baffle seals - like Wayne says !!!

Took some digital pic's the other day .... I'll post 'em as soon as I figure
out HOW to do it !

Rick & Wendy
541 R
----- Original Message -----
From: "David Ricker" <ricker@inherentsys.ca>
To: <rebel-builders@dcsol.com>
Sent: Friday, August 27, 2004 1:12 PM
Subject: Cooling Plenum, Was: Re: Importance of good baffle seal

Wayne you have brought to mind someting have been contemplating for a
while and
that is building a proper sealed plenum for the cooling air.

I have seen a couple of pictures in the mags. that show something like
this
where a complete box is formed around the engine in a way that mimics the
baffle
enclosure but since it is assembled before the cowl top is put on you can
be
sure that there are no uncontrolled air leaks. Of course you have to
attach
flexible ducts from the cowl intakes to the plenum but that can be done.

What do you guys think of the idea? Given Wayne's story it sounds like a
good
way to design out the doubts & problems of fitting & trimming baffle
rubbers and
wondering if that is why the engine runs hot.

The units I have seen were fibreglass and I believe blow molded in
polyethelyne,
of course blow mold tooling would be pricy......

Anyway, just wanted to toss the idea around & see what you think.

Dave

"Wayne G. O'Shea" wrote:
FYI for those guys complaining of high CHT's you might want to have a
good
look. Have a local guy here with an O-320 in a Luscombe that has been
removed and shoved engine back up the overhaulers @$$ 3 or 4 times in
the
last year and a half.... telling him he did a shit job on the overhaul.
Case
has made trips to ECI, cylinders have been redone twice etc and still
running high. One of our chapter members said to him last week.."you
really
should take that ratty baffle seal off and put some new stuff on...it
sure
might help". When he finally gave in and listened the CHT's dropped ONE
HUNDRED!!! degrees F! Makes you wonder if any of the nine or ten
thousand
dollars in extra work and a year of aircraft downtime (and the fun of
pulling a motor on and off using a tripod on the beach!!) and tinkering
actually did anything.

Cheers,
Wayne

-----------------------------------------------------
List archives located at:
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username "rebel" password "builder"
Subscription services located at:
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List administrator: mike.davis@dcsol.com
-----------------------------------------------------
--
David A. Ricker
Fall River, Nova Scotia
Canada






-----------------------------------------------------
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-----------------------------------------------------





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