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racerjerry
Joined: 15 Dec 2009
Posts: 202
Location: Deer Park, NY
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 Posted: Sun Jan 25, 2015 9:09 am Post subject: Re: 503 oil pump cable end wearing |
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How about making a new cable swivel (barrel) and using a new cable / splitter with a free end - no swaged fittings at oiler.
Make a new barrel from brass rod cross drilled to snugly fit cable.
Drill rod lengthwise and tap hole for machine screw thread - full length of barrel.
Move adjuster to a better position where it is not trying to kink cable.
Slide new barrel to best position and firmly tighten set screw to secure cable.
I would make the barrel slightly longer at the outboard end (cable hole not centered) to provide more meat for thread engagement. I would also use a short Allen bolt in place of the set screw to enable better tightening - no tiny Allen keys. You can Locktite the set screw, but it's probably not necessary.
Keep things clean and use a drop of oil - not WD-40 on the barrel. WD is primarily a moisture displacer with marginal lubricating properties.
If you want a belt & suspenders approach, you can splay the back end of the cable strands and solder the wire ends, but this really works well only on zinc coated cables - not stainless. Unfortunately, solder wicking up the cable strands makes the cable rigid and almost guarantees eventual breakage at the stress concentration point where the solder wicking ends.
Hope this helps.
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Jerry King |
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williamtsullivan(at)att.n
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| Posted: Sun Jan 25, 2015 9:11 am Post subject: 503 oil pump cable end wearing |
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I would be tempted to make one out of Oilite bronze. Self lubricating.
Bill Sullivan
--------------------------------------------
On Sun, 1/25/15, Tom Jones <nahsikhs(at)elltel.net> wrote:
Subject: Re: 503 oil pump cable end wearing
To: kolb-list(at)matronics.com
Date: Sunday, January 25, 2015, 11:34 AM
"Tom Jones" <nahsikhs(at)elltel.net>
> Tom, There's .002" difference between 5/16 and 8 mm,
.3125 vs .3145. I'd base the decision on which is cheaper, a
brass cable stop or a steel oil pump bell crank. If it were
me I'd rather the stop wear than the crank.Just a thought.
> Rick Girard
>
Our EAA club technical councilor has the same thinking as
you do Rick. I asked him why they didn't make the swedge out
of steel instead of brass. His reply was "Probably so
the swedge will wear and not wear out the pump lever.
--------
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA
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Tom Jones
Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA
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| Posted: Mon Jan 26, 2015 7:38 am Post subject: Re: 503 oil pump cable end wearing |
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I called Lockwood Aviation tech support this morning and told him my 503 brass oil injection cable barrel swedge had worn out quickly and asked if he had any ideas why. He dodged the question and said he only uses stainless steel swedges and stainless steel cables. He silver solders them.
They only make oil injection cables to fit the throttle cable splitters they sell but if I get him the exact length measurements and size of barrel swedges on the ends he would make a stainless steel cable and stainless barrel swedge to fit the Kitfox throttle reverser bellcrank.
He also said he sometimes bends the pump cable bracket to get better alignment of the cable. Several of you have suggested that too.
As far as excessive vibration of my engine, I don't notice any excessive vibration and have had comments from other pilots on how smooth it is in flight.
I really appreciate the number of replies I recieved from the Kolb forum on this question. There are a lot of good ideas for me to keep in mind.
Thank You all!
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Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA |
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John Hauck
Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)
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| Posted: Mon Jan 26, 2015 8:14 am Post subject: 503 oil pump cable end wearing |
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I go back to my comment of finding the cause before proceeding to bigger
band aids. For some reason, and the first to come to my mind is excessive
vibration, that fitting is wearing abnormally fast. The vibration may not
be felt in the airframe, but possibly could be a high frequency vibration
being generated by the 503 engine which is probably fan cooled. Something
is exciting that fitting to cause it to dance and wear. I don't pay a lot
of attention to two stroke Rotax engines anymore because I don't live in
that environment, and haven't since 1993. With my limited knowledge I
haven't heard of others having this particular problem.
If you don't find and fix what is causing your part to wear, when there are
thousands of others out there that are not wearing, what good is it to
replace with something else?
john h
mkIII
Titus, Alabama
As far as excessive vibration of my engine, I don't notice any excessive
vibration and have had comments from other pilots on how smooth it is in
flight.
I really appreciate the number of replies I recieved from the Kolb forum on
this question. There are a lot of good ideas for me to keep in mind.
--------
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA
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John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama |
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Tom Jones
Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA
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| Posted: Mon Jan 26, 2015 10:55 am Post subject: Re: 503 oil pump cable end wearing |
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| John Hauck wrote: | I go back to my comment of finding the cause before proceeding to bigger
band aids. For some reason, and the first to come to my mind is excessive
vibration, that fitting is wearing abnormally fast. The vibration may not
be felt in the airframe, but possibly could be a high frequency vibration
being generated by the 503 engine which is probably fan cooled. Something
is exciting that fitting to cause it to dance and wear. I don't pay a lot
of attention to two stroke Rotax engines anymore because I don't live in
that environment, and haven't since 1993. With my limited knowledge I
haven't heard of others having this particular problem.
If you don't find and fix what is causing your part to wear, when there are
thousands of others out there that are not wearing, what good is it to
replace with something else?
john h
mkIII
Titus, Alabama
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I appreciate your comments John. I will pursue that possibility too.
Thanks
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Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA |
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