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Matt Dralle
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Joined: 08 Nov 2005
Posts: 25203
Location: Livermore CA USA
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 Posted: Sun Oct 18, 2009 8:38 am Post subject: Oversized Oil Cooler Installation For IO-390... |
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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
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CB8-5_-_IO-390_-_063_Shadow_Doubler_For_SW10610R_Oil_Cooler_-_Version_1.0_-_October_12_2009.pdf |
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Matt Dralle
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ericrv6(at)yahoo.com
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| Posted: Wed Oct 21, 2009 9:40 am Post subject: Oversized Oil Cooler Installation For IO-390... |
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Matt it my be to far gone for you, but I would consider mounting it on the firewall. If you like I can send you a picture of a customers install on a rv8.
This would also allow you to control the air flow to the cooler better in the winter with an air controller.
Let me know.
Eric Faires
256-710-6120
www.nonstopaviation.com
eric(at)nonstopaviation.com
Muscle Shoals, Alabama
On Oct 18, 2009, at 11:37 AM, Matt Dralle <dralle(at)matronics.com> wrote:
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 972&log=90253&row=12
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com - Matt's All New RV-8 Construction Blog
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (2).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (3).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (4).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (5).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (9).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (10).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (15).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (1 .jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (20).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (21).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (23).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (24).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (25).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (26).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (27).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (2.jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (29).jpg>
<2009.10.11 - RV-8 - IO-390 And Oversized SW10610R Oil Cooler Installation (30).jpg>
<CB8-5 - IO-390 - 063 Shadow Doubler For SW10610R Oil Cooler - Version 1.0 - October 12 2009.jpg>
<CB8-5 - IO-390 - 063 Shadow Doubler For SW10610R Oil Cooler - Version 1.0 - October 12 2009.pdf>
| | - The Matronics RV8-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV8-List |
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