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charles.long(at)allisontr
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 Posted: Fri Sep 14, 2007 8:13 am Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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I've noticed some upper Rudder bushing wear on my 601 HDS after 130
hours of operation. I've replaced the bushing and reduced the end play
somewhat. The bushing wear was about .003" in the fore - aft direction.
The remainder of the wear was in the center hinge plate (aluminum). Is
anyone else experiencing this find of wear. Have you made changes to
address the issue?
Thanks
Chuck Long
Zodie Rocket
N601LE
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klaus(at)utdallas.edu
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| Posted: Fri Sep 14, 2007 1:00 pm Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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Hi Chuck,
Initially, I also had wear of the rudder hinge. To eliminate this, I used
brass tubing material to make bearings and expoxied them into the
aluminum brackets.
This has solved the problem. After 1,100 hours, there is not noticeable
increase of play.
Happy flying,
Klaus
--
Klaus Truemper
Professor Emeritus of Computer Science
University of Texas at Dallas
Erik Jonsson School of Engineering and
Computer Science EC31
P.O. Box 830688
Richardson, TX 75083-0688
(972) 883-2712
klaus(at)utdallas.edu
www.utdallas.edu/~klaus
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chris Sinfield
Joined: 28 Nov 2006
Posts: 270
Location: Sydney Australia
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| Posted: Sat Sep 15, 2007 2:27 pm Post subject: 601/ xl things to look out for down the line |
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Thanks Chuck and Klaus
We should have a folder set up somewhere to keep all this great info. As people are now up and flying, what things do we need to start keeping an eye out for , I guess a bit like service bulletins from builders..
How about it??
Klaus I have looked at your site, but have you done any other mods or investigation's lately?
Chris.. 
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ter_turn(at)YAHOO.COM
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| Posted: Sat Sep 15, 2007 4:18 pm Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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to amazing places on Yahoo! Travel. [quote][b]
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amyvega2005(at)earthlink.
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| Posted: Sat Sep 15, 2007 6:10 pm Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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like they say history allways repeats itself. just subscribe to the zenair newsletter and get thcomplete set, rudder loosening up as well as all the other fix its are in them.
Juan
--
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klaus(at)utdallas.edu
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| Posted: Mon Sep 17, 2007 11:54 am Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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Hi Chris,
You ask about recent changes/investigations.
Here are two items:
1. The banjo bolt at the bottom of the crankcase holding the banjo
fitting of the oil
return line, several times produced trouble over the years, when the
gaskets started leaking.
At one time, the safety wire broke, but fortunately did not leave the
bolt entirely and thus
held the bolt in place. We had smoke in the cabin due to a small amount
of oil having dripped
onto the muffler. An immediate return to the airport saved the day.
Most recently the fitting leaked again, and my AP friend at the airport
cautioned me
that the banjo bolt may be stretched. Indeed it was, as was evident from
the elongation
of the four holes in the bolt.
The lesson learned here is: If the banjo bolt starts leaking, it may be
wise to
examine the bolt for stretching instead of just using new gaskets and
reinstalling
a stretched bolt. If the holes show any amount of elongation, a new bolt
must
be used. The torque MUST be according to Rotax spec.
Do NOT guess the torque. Then use heavy-gauge safety wire to
safety the bolt.
Another lesson: It may be good idea to open the heater momentarily
during the
runup, to check for the smell of oil that may have dripped onto the
muffler, say during
overnight parking, and now is being vaporized. The amount of oil may be
so small that
it did not drip out of the cowl and thus was not detected during preflight.
2. Some years back I had improved on the original design of the 601HDS
toe brakes, but this year I learned that this is not good enough at gross
weight. So, starting this weekend, the toe brakes will be redesigned so that
they become much more effective. When this is completed, I will add pictures
and a description of the change on the website. If your 601 brakes also
seem feeble to you, you may want to look and see if our changes would
work for you. The change is made difficult by the size of the main brake
cylinders and the way they have been attached. We want to modify the system
without changing the design of the brake cylinders. That way, cylinders
can be readily swapped later against new ones if that ever becomes
necessary.
Happy Flying,
Klaus
--
Klaus Truemper
Professor Emeritus of Computer Science
University of Texas at Dallas
Erik Jonsson School of Engineering and
Computer Science EC31
P.O. Box 830688
Richardson, TX 75083-0688
(972) 883-2712
klaus(at)utdallas.edu
www.utdallas.edu/~klaus
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klaus(at)utdallas.edu
Guest
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| Posted: Mon Sep 17, 2007 12:43 pm Post subject: Upper Bushing Wear - Rudder Hinge on 601 |
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Hi Chris,
You ask about recent changes/investigations.
Here are two items:
1. Several times over the years, the banjo fitting at the bottom of the
Rotax 912 crankcase
began leaking. Each time I reinstalled the banjo bolt with new gaskets.
Most recently the fitting leaked again. My AP friend at the airport
cautioned me
that the banjo bolt may be stretched. Indeed it was, as was evident from
the elongation
of the four holes in the bolt.
The lesson learned here is: If the banjo fitting starts leaking, the banjo
banjo bolt must be checked for stretching instead of just using new
gaskets and reinstalling
a stretched bolt. If the holes show any amount of elongation, a new bolt
must
be used. The torque must be according to Rotax spec.
Heavy-gauge safety wire should be used to safety the bolt. The usual,
thin, safety wire
will not stand up to the high frequency vibration of the crankcase, as I
found
out some years ago.
It may be a good idea to open the heater momentarily during the
runup, to check for smell of oil that may have dripped onto the muffler,
say during
overnight parking, and that is being vaporized. The effect may be produced
by just a few drops of oil that are not detected during preflight. A leaking
banjo fitting may be the cause.
2. Several years ago we had improved the original design of the 601HDS
toe brakes, but this year we realized during a landing at gross
weight and high density altitude that the brakes must be further improved.
Starting this weekend, the toe brakes will be redesigned so that
they become much more effective. When this is completed, pictures and
a description of the change will be added to the website.
Happy Flying,
Klaus
--
Klaus Truemper
Professor Emeritus of Computer Science
University of Texas at Dallas
Erik Jonsson School of Engineering and
Computer Science EC31
P.O. Box 830688
Richardson, TX 75083-0688
(972) 883-2712
klaus(at)utdallas.edu
www.utdallas.edu/~klaus
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