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Fuel Pump Issue
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rleffler



Joined: 05 Nov 2006
Posts: 680

PostPosted: Sun Oct 20, 2013 1:11 pm    Post subject: Fuel Pump Issue Reply with quote

As several already are aware, I had some fuel flow issues on my first flight. At the time, in the air, I wasn’t quite sure what the issue may have been. It was initially looking like a blocked fuel line. The symptom was that the fuel pressure dropped significantly, but came back up with the electric fuel pump turned on and switching the tanks. I promptly landed and started looking for the root cause.

<![if !supportLists]>1. <![endif]>The left and right tank fuel flow (measured at the firewall, forward of the filter and pump) was 58 gallons/hour. Rules out a blockage aft of the firewall.
<![if !supportLists]>2. <![endif]>The fuel vents are not obstructed

I ran the engine in a static test. Was getting about 20psi on the engine fuel pump and about 26psi with the electric fuel pump enabled. Since this is all within specifications, this is the worst of all the scenarios. No root cause and everything seems to be working as designed.

This morning I flew for about an hour on flight #2.

When I turned off the electric fuel pump, fuel pressure started to immediately drop. I let it drop to about 10psi before I re-engaged the electric fuel pump. With the electric fuel pump running, I was getting 26psi. I repeated this scenario multiple times on both fuel tanks during the flight. Results were pretty consistent.

It’s looking like I may have a bad fuel pump on this 1 SNEW YIO-540-D4A5. I plan on giving Lycoming a call in the morning.

My questions is there any other scenarios that I’m overlooking that may yield similar symptoms?

Thanks,

bob


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PostPosted: Sun Oct 20, 2013 1:46 pm    Post subject: Fuel Pump Issue Reply with quote

With the info presented I think you're spot on. I agree with the call to Lycoming .... they should ship you a new pump. Up to you to do the R&R which has always been a PITA for me. My best guess is that there is some small piece of trash (don't know what else to call it) hung up in one of the valves.
Linn
On 10/20/2013 4:47 PM, Bob Leffler wrote:

[quote] <![endif]--> <![endif]-->
As several already are aware, I had some fuel flow issues on my first flight. At the time, in the air, I wasn’t quite sure what the issue may have been. It was initially looking like a blocked fuel line. The symptom was that the fuel pressure dropped significantly, but came back up with the electric fuel pump turned on and switching the tanks. I promptly landed and started looking for the root cause.

1. The left and right tank fuel flow (measured at the firewall, forward of the filter and pump) was 58 gallons/hour. Rules out a blockage aft of the firewall.
2. The fuel vents are not obstructed

I ran the engine in a static test. Was getting about 20psi on the engine fuel pump and about 26psi with the electric fuel pump enabled. Since this is all within specifications, this is the worst of all the scenarios. No root cause and everything seems to be working as designed.

This morning I flew for about an hour on flight #2.

When I turned off the electric fuel pump, fuel pressure started to immediately drop. I let it drop to about 10psi before I re-engaged the electric fuel pump. With the electric fuel pump running, I was getting 26psi. I repeated this scenario multiple times on both fuel tanks during the flight. Results were pretty consistent.

It’s looking like I may have a bad fuel pump on this 1 SNEW YIO-540-D4A5. I plan on giving Lycoming a call in the morning.

My questions is there any other scenarios that I’m overlooking that may yield similar symptoms?

Thanks,

bob


Quote:


No virus found in this message.
Checked by AVG - www.avg.com
10/20/13 [b]


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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Sun Oct 20, 2013 2:37 pm    Post subject: Fuel Pump Issue Reply with quote

You could download your engine data from your EFIS, and look at both
fuel pressure and fuel flow simultaneously. I don't think there is an
issue with your fuel pressure sensor, but it would be good to see what
was happening on fuel flow at the same time pressure was dropping. The
mechanical pump is supposed to be able to handle up to -2 psi input, i.e
overcoming an uphill flow on the input side.
There is one other possibility. You could have a leak between the
electric pump and the mechanical pump. If that is the case, the
mechanical pump sucks air through the leak, which reduces the pressure
to the engine, while the electric pump will over come this.
Rule out the chance of an air leak between boost pump and mechanical
before assuming that mechanical pump is bad.

On 10/20/2013 2:46 PM, Linn Walters wrote:
Quote:
With the info presented I think you're spot on. I agree with the call
to Lycoming .... they should ship you a new pump. Up to you to do the
R&R which has always been a PITA for me. My best guess is that there
is some small piece of trash (don't know what else to call it) hung up
in one of the valves.
Linn
On 10/20/2013 4:47 PM, Bob Leffler wrote:
>
> As several already are aware, I had some fuel flow issues on my first
> flight. At the time, in the air, I wasn’t quite sure what the issue
> may have been. It was initially looking like a blocked fuel line. The
> symptom was that the fuel pressure dropped significantly, but came
> back up with the electric fuel pump turned on and switching the
> tanks. I promptly landed and started looking for the root cause.
>
> 1.The left and right tank fuel flow (measured at the firewall,
> forward of the filter and pump) was 58 gallons/hour. Rules out a
> blockage aft of the firewall.
>
> 2.The fuel vents are not obstructed
>
> I ran the engine in a static test. Was getting about 20psi on the
> engine fuel pump and about 26psi with the electric fuel pump enabled.
> Since this is all within specifications, this is the worst of all the
> scenarios. No root cause and everything seems to be working as designed.
>
> This morning I flew for about an hour on flight #2.
>
> When I turned off the electric fuel pump, fuel pressure started to
> immediately drop. I let it drop to about 10psi before I re-engaged
> the electric fuel pump. With the electric fuel pump running, I was
> getting 26psi. I repeated this scenario multiple times on both fuel
> tanks during the flight. Results were pretty consistent.
>
> It’s looking like I may have a bad fuel pump on this 1 SNEW
> YIO-540-D4A5. I plan on giving Lycoming a call in the morning.
>
> My questions is there any other scenarios that I’m overlooking that
> may yield similar symptoms?
>
> Thanks,
>
> bob
>
> *
> *
>
> No virus found in this message.
> Checked by AVG - www.avg.com <http://www.avg.com>
> 10/20/13
>

*
*


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KCHD
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rleffler



Joined: 05 Nov 2006
Posts: 680

PostPosted: Sun Oct 20, 2013 3:05 pm    Post subject: Fuel Pump Issue Reply with quote

Here’s the Fuel Flow and Fuel Pressure overlaid. The dips are consistent when I turned off the electric fuel pump. An interesting anomaly is that the fuel pressure is higher during taxi with the boost pump off.


[img]cid:image003.jpg(at)01CECDC4.9593AB50[/img]

Finding a fuel leak is pretty straight forward, especially with the aid of the blue dye. How do you find a connection that doesn’t leak fuel, but does allow air?

bob

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PostPosted: Sun Oct 20, 2013 3:10 pm    Post subject: Fuel Pump Issue Reply with quote

Good point Kelly. I had an air leak in the fuel line between the tank
and wobble pump on my Pitts. It almost drove me nuts .... well, more
nuts! I couldn't see that the rudder pedal had worn a hole in the hard
line. My fault .... the result of poor repairs .... but it was really
difficult to find since the problem .... engine surged like an old
Sopwith .... because the rudder pedal would cover the hole and 'fix' the
problem!!! The leaking fuel was so slight that it evaporated and left
no smell. Good call!
Linn

On 10/20/2013 6:37 PM, Kelly McMullen wrote:
Quote:


You could download your engine data from your EFIS, and look at both
fuel pressure and fuel flow simultaneously. I don't think there is an
issue with your fuel pressure sensor, but it would be good to see what
was happening on fuel flow at the same time pressure was dropping. The
mechanical pump is supposed to be able to handle up to -2 psi input,
i.e overcoming an uphill flow on the input side.
There is one other possibility. You could have a leak between the
electric pump and the mechanical pump. If that is the case, the
mechanical pump sucks air through the leak, which reduces the pressure
to the engine, while the electric pump will over come this.
Rule out the chance of an air leak between boost pump and mechanical
before assuming that mechanical pump is bad.

On 10/20/2013 2:46 PM, Linn Walters wrote:
> With the info presented I think you're spot on. I agree with the call
> to Lycoming .... they should ship you a new pump. Up to you to do the
> R&R which has always been a PITA for me. My best guess is that there
> is some small piece of trash (don't know what else to call it) hung
> up in one of the valves.
> Linn
> On 10/20/2013 4:47 PM, Bob Leffler wrote:
>>
>> As several already are aware, I had some fuel flow issues on my
>> first flight. At the time, in the air, I wasn’t quite sure what the
>> issue may have been. It was initially looking like a blocked fuel
>> line. The symptom was that the fuel pressure dropped significantly,
>> but came back up with the electric fuel pump turned on and switching
>> the tanks. I promptly landed and started looking for the root cause.
>>
>> 1.The left and right tank fuel flow (measured at the firewall,
>> forward of the filter and pump) was 58 gallons/hour. Rules out a
>> blockage aft of the firewall.
>>
>> 2.The fuel vents are not obstructed
>>
>> I ran the engine in a static test. Was getting about 20psi on the
>> engine fuel pump and about 26psi with the electric fuel pump
>> enabled. Since this is all within specifications, this is the worst
>> of all the scenarios. No root cause and everything seems to be
>> working as designed.
>>
>> This morning I flew for about an hour on flight #2.
>>
>> When I turned off the electric fuel pump, fuel pressure started to
>> immediately drop. I let it drop to about 10psi before I re-engaged
>> the electric fuel pump. With the electric fuel pump running, I was
>> getting 26psi. I repeated this scenario multiple times on both fuel
>> tanks during the flight. Results were pretty consistent.
>>
>> It’s looking like I may have a bad fuel pump on this 1 SNEW
>> YIO-540-D4A5. I plan on giving Lycoming a call in the morning.
>>
>> My questions is there any other scenarios that I’m overlooking that
>> may yield similar symptoms?
>>
>> Thanks,
>>
>> bob
>>
>> *
>>
>>
>> *
>>
>> No virus found in this message.
>> Checked by AVG - www.avg.com <http://www.avg.com>
>> 10/20/13
>>
>
> *
> *
-----
No virus found in this message.
Checked by AVG - www.avg.com


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PostPosted: Sun Oct 20, 2013 3:11 pm    Post subject: Fuel Pump Issue Reply with quote

Since you can't reproduce this on the ground I am wondering if you have an airflow created vacuum on the tank vents. I may be all wet, but if there is a difference between flight and ground, it shouldn't be a mechanical problem.

Gary Specketer


From: "Bob Leffler" <rv(at)thelefflers.com>n't
To: rv10-list(at)matronics.com
Sent: Sunday, October 20, 2013 4:47:25 PM
Subject: Fuel Pump Issue


As several already are aware, I had some fuel flow issues on my first flight. At the time, in the air, I wasn’t quite sure what the issue may have been. It was initially looking like a blocked fuel line. The symptom was that the fuel pressure dropped significantly, but came back up with the electric fuel pump turned on and switching the tanks. I promptly landed and started looking for the root cause.

1. The left and right tank fuel flow (measured at the firewall, forward of the filter and pump) was 58 gallons/hour. Rules out a blockage aft of the firewall.
2. The fuel vents are not obstructed

I ran the engine in a static test. Was getting about 20psi on the engine fuel pump and about 26psi with the electric fuel pump enabled. Since this is all within specifications, this is the worst of all the scenarios. No root cause and everything seems to be working as designed.

This morning I flew for about an hour on flight #2.

When I turned off the electric fuel pump, fuel pressure started to immediately drop. I let it drop to about 10psi before I re-engaged the electric fuel pump. With the electric fuel pump running, I was getting 26psi. I repeated this scenario multiple times on both fuel tanks during the flight. Results were pretty consistent.

It’s looking like I may have a bad fuel pump on this 1 SNEW YIO-540-D4A5. I plan on giving Lycoming a call in the morning.

My questions is there any other scenarios that I’m overlooking that may yield similar symptoms?

Thanks,

bob


[quote]

get=_blank>http://www.matronics.com/Navigator?RV10-List
p://forums.matronics.com
blank>http://www.matronics.com/contribution

[b]


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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Sun Oct 20, 2013 4:05 pm    Post subject: Fuel Pump Issue Reply with quote

On the ground, throttle and mixture full aft, idle cutoff; turn on
electric pump with tunnel open and cowling off. After pressure comes up,
look for leaks. Anything that lets in air under suction will leak under
pressure. Ideally a couple observers, one in reach of the switch to kill
pressure as soon as leak is spotted.

On 10/20/2013 3:45 PM, Bob Leffler wrote:
[quote]
Here’s the Fuel Flow and Fuel Pressure overlaid. The dips are
consistent when I turned off the electric fuel pump. An interesting
anomaly is that the fuel pressure is higher during taxi with the boost
pump off.

Finding a fuel leak is pretty straight forward, especially with the
aid of the blue dye. How do you find a connection that doesn’t leak
fuel, but does allow air?

bob

--


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A&P/IA, EAA Tech Counselor # 5286
KCHD
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cooprv7(at)yahoo.com
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PostPosted: Sun Oct 20, 2013 4:54 pm    Post subject: Fuel Pump Issue Reply with quote

The likely culprit does sound like the fuel pump, although the fact that all is well on the ground is interesting. My first project was a Q-2 and when I upgraded from the VW engine to an O-200 I had lots of fuel starvation issues. After an eternity I chased it down to the fact that when I had to modify the shape of the cowl it created an area of negative pressure at the fuel vent. While not too likely your issue, I'd make sure you have your vents as directed in the plans. Even something as simple as having the angled cutoff facing the wrong way could make for interesting problems.

Good luck,
Marcus

On Oct 20, 2013, at 7:11 PM, speckter(at)comcast.net (speckter(at)comcast.net) wrote:
Since you can't reproduce this on the ground I am wondering if you have an airflow created vacuum on the tank vents. I may be all wet, but if there is a difference between flight and ground, it shouldn't be a mechanical problem.

Gary Specketer

From: "Bob Leffler" <rv(at)thelefflers.com (rv(at)thelefflers.com)>n't
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Sent: Sunday, October 20, 2013 4:47:25 PM
Subject: Fuel Pump Issue
As several already are aware, I had some fuel flow issues on my first flight. At the time, in the air, I wasn’t quite sure what the issue may have been. It was initially looking like a blocked fuel line. The symptom was that the fuel pressure dropped significantly, but came back up with the electric fuel pump turned on and switching the tanks. I promptly landed and started looking for the root cause.

1. The left and right tank fuel flow (measured at the firewall, forward of the filter and pump) was 58 gallons/hour. Rules out a blockage aft of the firewall.
2. The fuel vents are not obstructed

I ran the engine in a static test. Was getting about 20psi on the engine fuel pump and about 26psi with the electric fuel pump enabled. Since this is all within specifications, this is the worst of all the scenarios. No root cause and everything seems to be working as designed.

This morning I flew for about an hour on flight #2.

When I turned off the electric fuel pump, fuel pressure started to immediately drop. I let it drop to about 10psi before I re-engaged the electric fuel pump. With the electric fuel pump running, I was getting 26psi. I repeated this scenario multiple times on both fuel tanks during the flight. Results were pretty consistent.

It’s looking like I may have a bad fuel pump on this 1 SNEW YIO-540-D4A5. I plan on giving Lycoming a call in the morning.

My questions is there any other scenarios that I’m overlooking that may yield similar symptoms?

Thanks,

bob



Quote:


get=_blank>http://www.matronics.com/Navigator?RV10-List
p://forums.matronics.com
blank>http://www.matronics.com/contribution



style="color: purple; text-decoration: underline; ">http://www.matronics.com/Navigator?RV10-List
purple; text-decoration: underline; ">http://forums.matronics.com
style="color: purple; text-decoration: underline; ">http://www.matronics.com/contribution



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PostPosted: Sun Oct 20, 2013 5:05 pm    Post subject: Fuel Pump Issue Reply with quote



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rleffler



Joined: 05 Nov 2006
Posts: 680

PostPosted: Mon Oct 21, 2013 3:55 pm    Post subject: Fuel Pump Issue Reply with quote

After shipping the data logs from my two flights and ground testing to Lycoming, they are recommending replacing my fuel pump. Naturally, I am just outside the warranty period.

They recommended a part #62B26931, which I can find that it is an approved substitute for the installed part, which is a LW15473. Anyone know what the difference may be?

Bob

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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Mon Oct 21, 2013 6:28 pm    Post subject: Fuel Pump Issue Reply with quote

Looks like Lycoming has approved that part number. Have no idea the
difference. Maybe different vendor?
On 10/21/2013 4:55 PM, Bob Leffler wrote:
Quote:


After shipping the data logs from my two flights and ground testing to Lycoming, they are recommending replacing my fuel pump. Naturally, I am just outside the warranty period.

They recommended a part #62B26931, which I can find that it is an approved substitute for the installed part, which is a LW15473. Anyone know what the difference may be?

Bob

Sent from my iPad




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PostPosted: Tue Oct 22, 2013 4:37 am    Post subject: Fuel Pump Issue Reply with quote

Lycoming is notorious for part number changes. Any time they change a
vendor they change a P/N. Tempest makes the pump also. Call Justin at
Quality Aircraft Acc.

Allen Barrett

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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Tue Oct 22, 2013 6:13 am    Post subject: Fuel Pump Issue Reply with quote

Seems rather poor customer service to sell an experimental engine, that
they know won't be put into service for many months after the sale, if
not a year or so, to not cover a fuel pump that only has an hour or two
of actual operation.

On 10/22/2013 5:39 AM, BPA wrote:
[quote]

Lycoming is notorious for part number changes. Any time they change a
vendor they change a P/N. Tempest makes the pump also. Call Justin at
Quality Aircraft Acc.

Allen Barrett

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rleffler



Joined: 05 Nov 2006
Posts: 680

PostPosted: Tue Oct 22, 2013 6:27 am    Post subject: Fuel Pump Issue Reply with quote

Allen,

Any opinion on the differences between the Lycoming part and the Tempest? The Tempest is $100 less expensive.

Thanks,

Bob

Sent from my iPad

[quote] On Oct 22, 2013, at 8:39 AM, "BPA" <BPA(at)bpaengines.com> wrote:



Lycoming is notorious for part number changes. Any time they change a
vendor they change a P/N. Tempest makes the pump also. Call Justin at
Quality Aircraft Acc.

Allen Barrett

--


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PostPosted: Tue Oct 22, 2013 6:32 am    Post subject: Fuel Pump Issue Reply with quote

They seem to work just fine in the test cell and I haven't heard of any
field issues.

Allen

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Kelly McMullen



Joined: 16 Apr 2008
Posts: 1188
Location: Sun Lakes AZ

PostPosted: Tue Oct 22, 2013 6:35 am    Post subject: Fuel Pump Issue Reply with quote

Your guess is as good as any. Lycomng platinum gold dust sprinkled on the paperwork?

Go with the Tempest and spend the difference on 100LL/

On Tue, Oct 22, 2013 at 7:26 AM, Bob Leffler <rv(at)thelefflers.com (rv(at)thelefflers.com)> wrote:
[quote] --> RV10-List message posted by: Bob Leffler <rv(at)thelefflers.com (rv(at)thelefflers.com)>


Allen,

Any opinion on the differences between the Lycoming part and the Tempest?  The Tempest is $100 less expensive.

Thanks,

Bob

Sent from my iPad


Quote:
On Oct 22, 2013, at 8:39 AM, "BPA" <BPA(at)bpaengines.com (BPA(at)bpaengines.com)> wrote:
>

> --> RV10-List message posted by: "BPA" <BPA(at)bpaengines.com (BPA(at)bpaengines.com)>
>
> Lycoming is notorious for part number changes. Any time they change a
> vendor they change a P/N. Tempest makes the pump also. Call Justin at
> Quality Aircraft Acc.
>
> Allen Barrett
>
> --


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bwestfall



Joined: 22 Oct 2008
Posts: 131
Location: Portland, OR

PostPosted: Tue Oct 22, 2013 8:57 am    Post subject: Fuel Pump Issue Reply with quote

Geez Kelly what do you expect for $45,800... decent customer service? Smile.

-Ben

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Kelly McMullen



Joined: 16 Apr 2008
Posts: 1188
Location: Sun Lakes AZ

PostPosted: Tue Oct 22, 2013 8:14 pm    Post subject: Fuel Pump Issue Reply with quote

Well, I'm sure it would drive Lyc into bankruptcy to warrant that $200 pump.

On Tue, Oct 22, 2013 at 9:50 AM, Ben Westfall <rv10(at)sinkrate.com (rv10(at)sinkrate.com)> wrote:
[quote]--> RV10-List message posted by: "Ben Westfall" <rv10(at)sinkrate.com (rv10(at)sinkrate.com)>

Geez Kelly what do you expect for $45,800... decent customer service?  Smile.

-Ben

--


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Kelly McMullen
A&P/IA, EAA Tech Counselor
KCHD
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rleffler



Joined: 05 Nov 2006
Posts: 680

PostPosted: Wed Oct 23, 2013 2:12 pm    Post subject: Fuel Pump Issue Reply with quote

Just an update.......

I sent off all the engine monitor data to Lycoming. They think it's the fuel pump. Fortunately, they authorized a warranty repair.

Bob


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Bob Leffler
N410BL - Phase I
http://mykitlog.com/rleffler
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hotwheels



Joined: 01 Jun 2007
Posts: 240

PostPosted: Mon Oct 28, 2013 5:42 am    Post subject: Re: Fuel Pump Issue Reply with quote

I went out on a weekend x-country flight (6 hours) and noticed some strange behavior.

In cruise, my fuel flow readings would occasionally fluctuate between 9.5 and 10.5 gph without me touching anything... At the same time, the fuel psi changed from ~18 (normal) and 14psi. At 14 the engine would stumble. Same behavior on either tank... even after richening the mixture. Turning on the electric fuel pump caused the symptom to go away. No obvious leaks and no fuel smells.

I'm wondering if I too have an issue lurking in the pump department. It's nearly time for my annual, so it's good timing as everything has to come apart anyway.

Jay
N433RV - flying


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