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Matt Dralle
Site Admin
Joined: 08 Nov 2005
Posts: 25858
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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dsvs(at)ca.rr.com
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| Posted: Sun Oct 18, 2009 5:29 pm Post subject: Oversized Oil Cooler Installation For IO-390... |
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Matt,
Nice work around and great pictures. I can't tell but it looks like you
used aluminum fittings on the oil cooler. If this is true you need to know
that they are very easy to gall. Dan C had this problem. Pacific Oil Cooler
was able to repair the damage. Just a head's up to try to keep you from
future problems. BTW the normal recommendation is to use steel fittings on
the oil cooler.
Don VS RV7 Flying
--
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Matt Dralle
Site Admin
Joined: 08 Nov 2005
Posts: 25858
Location: Livermore CA USA
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| Posted: Sun Oct 18, 2009 6:56 pm Post subject: Oversized Oil Cooler Installation For IO-390... |
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Hi Don,
Thanks for the feedback. Right now I've just got the AN822-8D aluminum fittings that Van's includes with the kit screwed into the oil cooler finger tight. I just checked Van's site and didn't find any steel versions of the AN822-8D. Is this something that Van's carries or is ACS a better bet? Do you happen to have a part number?
Thanks!
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com - Matt's RV-8 Construction Blog
At 05:25 PM 10/18/2009 Sunday, you wrote:
[quote]
Matt,
Nice work around and great pictures. I can't tell but it looks like you
used aluminum fittings on the oil cooler. If this is true you need to know
that they are very easy to gall. Dan C had this problem. Pacific Oil Cooler
was able to repair the damage. Just a head's up to try to keep you from
future problems. BTW the normal recommendation is to use steel fittings on
the oil cooler.
Don VS RV7 Flying
--
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Matt Dralle
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dsvs(at)ca.rr.com
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| Posted: Sun Oct 18, 2009 7:24 pm Post subject: Oversized Oil Cooler Installation For IO-390... |
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Matt,
I got them from Pacific Oil Cooler, http://www.oilcoolers.com/ . Van's does
not stock them as far as I know. ACS does but I do nort know the part #
Don VS RV& flying
--
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gyoung
Joined: 09 Jan 2006
Posts: 211
Location: Republic of Texas
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| Posted: Sun Oct 18, 2009 7:53 pm Post subject: Oversized Oil Cooler Installation For IO-390... |
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It would be AN822-8. The D is for Dural, i.e. aluminum. Normally -8 and
above size fittings are considered strong enough in aluminum for engine
installations. -6 and below use steel.
Regards,
Greg Young
[quote] --
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chaskuss(at)yahoo.com
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| Posted: Mon Oct 19, 2009 3:45 am Post subject: Oversized Oil Cooler Installation For IO-390... |
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Matt,
The letter D at the end of the AN822-8D part number specifies that the part is made of aluminum [Dural alloy]. Simply omit the D [AN822-8] to obtain the same part in steel. This rule applies to all AN hydraulic fittings.
http://www.aircraftspruce.com/catalog/hapages/an822.php
Charlie Kuss
PS Using straight or 45 degree fittings will improve oil flow to and from the cooler, if space allows. 90 degree fittings should only be used when the less restrictive straight [AN816-8] or 45 degree [AN823-8] fittings will not work.
http://www.aircraftspruce.com/catalog/hapages/an823.php
http://www.aircraftspruce.com/catalog/hapages/an816.php
--- On Sun, 10/18/09, Matt Dralle <dralle(at)matronics.com> wrote:
[quote] From: Matt Dralle <dralle(at)matronics.com>
Subject: RE: Oversized Oil Cooler Installation For IO-390...
To: rv-list(at)matronics.com
Date: Sunday, October 18, 2009, 10:47 PM
Matt Dralle <dralle(at)matronics.com>
Hi Don,
Thanks for the feedback. Right now I've just got the
AN822-8D aluminum fittings that Van's includes with the kit
screwed into the oil cooler finger tight. I just
checked Van's site and didn't find any steel versions of the
AN822-8D. Is this something that Van's carries or is
ACS a better bet? Do you happen to have a part
number?
Thanks!
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com - Matt's RV-8 Construction
Blog
At 05:25 PM 10/18/2009 Sunday, you wrote:
>
>
>Matt,
>Nice work around and great pictures. I can't tell
but it looks like you
>used aluminum fittings on the oil cooler. If this
is true you need to know
>that they are very easy to gall. Dan C had this
problem. Pacific Oil Cooler
>was able to repair the damage. Just a head's up
to try to keep you from
>future problems. BTW the normal recommendation is
to use steel fittings on
>the oil cooler.
>Don VS RV7 Flying
>
>--
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pitts_pilot(at)bellsouth.
Guest
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| Posted: Mon Oct 19, 2009 5:55 am Post subject: Oversized Oil Cooler Installation For IO-390... |
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Reasons for steel Vs. aluminum fittings in the engine compartment
abound. The only credible one I've heard is that the steel will be in
place long after the aluminum fitting has disappeared due to fire. That
makes sense to me. However, I have found no FACTUAL information that
one type of fitting ever helped/caused a fire related incident. That
doesn't mean that the facts aren't out there .... it just means I
haven't found them. I will admit that I have had aluminum fittings in
my Pitts for 28 years .... they were lighter, plentiful, less cost
..... so I used them.
Linn
Don wrote:
[quote]
Matt,
I got them from Pacific Oil Cooler, http://www.oilcoolers.com/ . Van's does
not stock them as far as I know. ACS does but I do nort know the part #
Don VS RV& flying
--
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Bruce(at)glasair.org
Guest
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| Posted: Mon Oct 19, 2009 6:13 am Post subject: Oversized Oil Cooler Installation For IO-390... |
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I don't think steel is preferred for fire suppression. Steel is
preferred for vibration protection. The fatigue life of aluminum is
quite short. Common practice is to use steel on any fitting that hangs
off the engine.
Bruce
www.Glasair.org
--
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dsvs(at)ca.rr.com
Guest
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| Posted: Mon Oct 19, 2009 6:43 pm Post subject: Oversized Oil Cooler Installation For IO-390... |
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Aluminum also galls very easily when tightened against steel.
--
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