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engine baffle safety wire

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sarg314(at)comcast.net
Guest

Posted: Thu Dec 28, 2006 3:35 pm Post subject: engine baffle safety wire

My engine baffles were installed long ago, but I never put in the 

safety wire on the underside of the cylinders that is supposed to pull 

the lower ends of the baffles tight around the cooling fins.  I just 

stretched a string across there today and it is clear that the safety 

wire would rub against one of the oil return lines.  It's the same story 

on both sides of the engine.



    I guess I could extend the little flange of the baffle to reposition 

the safety wire attach point lower, or I could rivet a little bracket of 

some sort to the to the intercylinder baffle to push the wire down.  

(Come to think of it, it would probably wear through anything I put there.)



    Does any one have a tried and true solution to this problem? Or am I 

missing something here?

--

Tom S., RV-6A, wiring

dan(at)rvproject.com
Guest

Posted: Thu Dec 28, 2006 4:34 pm Post subject: engine baffle safety wire

As per Van's, I used thick-walled plastic tubing...the same stuff used for 

brake tubing in some spots.  The safety wire runs through the plastic, and 

the plastic serves as anti-chafe.



)_( Dan

RV-7 N714D (1162 hours)

www.rvproject.com / www.weathermeister.com



---

Vanremog(at)aol.com
Guest

Posted: Thu Dec 28, 2006 5:00 pm Post subject: engine baffle safety wire

In a message dated 12/28/2006 3:39:35 P.M. Pacific Standard Time,  sarg314(at)comcast.net writes:

  	  Quote: 	
		  My    engine baffles were installed long ago, but I never put in the 

safety wire    on the underside of the cylinders that is supposed to pull 

the lower ends    of the baffles tight around the cooling fins.  I just 

stretched a    string across there today and it is clear that the safety 

wire would rub    against one of the oil return lines.  It's the same story 

on both    sides of the engine.



    I guess I could extend the little    flange of the baffle to reposition 

the safety wire attach point lower, or    I could rivet a little bracket of 

some sort to the to the intercylinder    baffle to push the wire down.  

(Come to think of it, it would    probably wear through anything I put there.)



    Does any one    have a tried and true solution to this problem? Or am I 

missing something    here?

	


 

 ======================================

  

 Mine are threaded rods from the hobby store that I bent a joggle  in fitted with springs (to allow for movement) and high temp lock nuts and  they have worked fine.   

 GV (RV-6A  N1GV O-360-A1A, C/S, Flying 830hrs, Silicon Valley, CA)  



  [quote][b]

rv8a2001(at)yahoo.com
Guest

Posted: Thu Dec 28, 2006 5:03 pm Post subject: engine baffle safety wire

I used a threaded rod.....(4-40? dont remember) to pull the baffles together and to keep it from rubbing on the tubes I placed car fuel line over the drain tubes....you know, slice it down one side and slip it on, 400 plus hours and it works great.....so far!

 

Scott Bilinski

RV-8a

 



 ---

George McNutt

Joined: 09 Jan 2006
Posts: 30

Posted: Thu Dec 28, 2006 5:04 pm Post subject: engine baffle safety wire

Hi Tom



Wire will eventually cut through the baffle tabs. If you want a nice fix 

use 1/8 stainless welding rod instead of wire.

After cutting and forming, thread each end of the rod for #4 fiber lock 

nuts. To allow for expansion & contraction use washers then small 

compression springs between the nut and baffle flange  (flanges are held 

by spring pressure not nut tension). The welding rod is stiff enough 

that it does not need to run straight and can be shaped to fit 

under/around the oil line.



George in Langley BC



Tom wrote ----------------------------

 	  Quote: 	
		      My engine baffles were installed long ago, but I never put in the 

 safety wire on the underside of the cylinders that is supposed to pull 

 the lower ends of the baffles tight around the cooling fins.  I just 

 stretched a string across there today and it is clear that the safety 

 wire would rub against one of the oil return lines.  It's the same 

 story on both sides of the engine.



    I guess I could extend the little flange of the baffle to 

 reposition the safety wire attach point lower, or I could rivet a 

 little bracket of some sort to the to the intercylinder baffle to push 

 the wire down.  (Come to think of it, it would probably wear through 

 anything I put there.)



    Does any one have a tried and true solution to this problem? Or am 

 I missing something here?

 -- 

 Tom S., RV-6A, wiring

bertrv6(at)highstream.net
Guest

Posted: Thu Dec 28, 2006 5:07 pm Post subject: engine baffle safety wire

Quoting Dan Checkoway <dan(at)rvproject.com>:



[quote] 



 As per Van's, I used thick-walled plastic tubing...the same stuff used for

 brake tubing in some spots.  The safety wire runs through the plastic, and

 the plastic serves as anti-chafe.



 )_( Dan

 RV-7 N714D (1162 hours)

 www.rvproject.com / www.weathermeister.com



 ---

bo124rs(at)hotmail.com
Guest

Posted: Thu Dec 28, 2006 6:38 pm Post subject: engine baffle safety wire

 	  Quote: 	
		  From: G McNutt <gmcnutt(at)shaw.ca>


	


 	  Quote: 	
		  Wire will eventually cut through the baffle tabs. George in Langley BC




	


George, nice fix.  However, Tom if you do want to go with the safety wire, 

use a washer on the outside of the tab.  This will add more meat than just 

the tab and address the issue of the safety wire cutting through the tab.



Dana Overall

Richmond, KY i39

RV-7 slider, Imron black, "Black Magic"

O 360 A1A, C/S C2YK-1BF/F7666A4

http://rvflying.tripod.com/blackwing1.jpg

http://rvflying.tripod.com

do not archive



_________________________________________________________________

Get live scores and news about your team: Add the Live.com Football Page 

www.live.com/?addtemplate=football&icid=T001MSN30A0701

phil(at)petrasoft.net
Guest

Posted: Thu Dec 28, 2006 7:29 pm Post subject: engine baffle safety wire

Yep, that's the ticket.  Simple and effective but Dan forgot his own  

hint about using small washers on each end of the safety wire to keep  

the wire from pulling through the aluminum baffles.



Don't make it more complicated than it needs to be.



Phil

On Dec 28, 2006, at 6:33 PM, Dan Checkoway wrote:



[quote] 



 As per Van's, I used thick-walled plastic tubing...the same stuff  

 used for brake tubing in some spots.  The safety wire runs through  

 the plastic, and the plastic serves as anti-chafe.



 )_( Dan

 RV-7 N714D (1162 hours)

 www.rvproject.com / www.weathermeister.com



 ---

randy(at)romeolima.com
Guest

Posted: Thu Dec 28, 2006 8:43 pm Post subject: engine baffle safety wire

I used a bit different method... I first riveted a doubler on the flanges, 

then used a pop rivet where the safety wire goes through the flange with the 

mandrel punched out. The safety wire goes through the pop rivet then. 

Provides better protection from the safety wire than a washer.



Randy Lervold

www.rv-3.com

www.rv-8.com



---

Terry Watson

Joined: 09 Jan 2006
Posts: 290
Location: Seattle, WA USA

Posted: Thu Dec 28, 2006 9:31 pm Post subject: engine baffle safety wire

I believe the plans for the baffle show a fairly heavy aluminum doubler at

those tabs. I think I used 1/8" stock.



Terry




 	  Quote: 	
		  From: G McNutt <gmcnutt(at)shaw.ca>


	


 	  Quote: 	
		  Wire will eventually cut through the baffle tabs. George in Langley BC




	


George, nice fix.  However, Tom if you do want to go with the safety wire, 

use a washer on the outside of the tab.  This will add more meat than just 

the tab and address the issue of the safety wire cutting through the tab.



Dana Overall

Richmond, KY i39

RV-7 slider, Imron black, "Black Magic"

O 360 A1A, C/S C2YK-1BF/F7666A4

http://rvflying.tripod.com/blackwing1.jpg

http://rvflying.tripod.com

do not archive

Mark Phillips in TN

Joined: 10 Jan 2006
Posts: 431
Location: Columbia, TN

Posted: Fri Dec 29, 2006 5:35 am Post subject: engine baffle safety wire

In a message dated 12/28/2006 9:34:14 PM Central Standard Time, phil(at)petrasoft.net writes:

  	  Quote: 	
		  Yep, that's the ticket.  Simple and effective but Dan forgot his own  

hint about using small washers on each end of the safety wire to keep  

the wire from pulling through the aluminum baffles. 	


 >>>

 I riveted "doublers" (maybe .040 or .063?) the same size as the tabs on the ends of the baffles before drilling the holes for the safety wire- no significant wear from safety wire so far (375 hrs) but would be hard to do with baffles already installed...

  

 Mark

  [quote][b]

_________________
From The PossumWorks...

rv8striker(at)hotmail.com
Guest

Posted: Fri Dec 29, 2006 6:17 am Post subject: engine baffle safety wire

I'll throw my two cents worth in on this on.



I used the twisted safety wire inside the tubing as some have mentioned and 

attached the wire to the reinforced tabs with a cotter pin bent like a "T". 

The wires attach to the eyes of the cotter pins at each end. I put a washer 

under the cotter pin "legs" to protect from chafing the tabs. I just 

finished my first annual and they look like new.



I can send a picture (1000 words?) to anyone wanting one off list.



Steve Struyk

RV-8, 75 hours.

St. Charles, MO

---

Hopperdhh(at)aol.com
Guest

Posted: Fri Dec 29, 2006 7:29 am Post subject: engine baffle safety wire

You guys are all paranoid!  (Come on, its a joke!)  Just wire 'em up and get the thing flying.  Mine has been flying 2 years now and I can't see where the safety wire has cut into the baffle at all.  When it does, I'll fix it.  As for the oil return lines, I think I just bent them up or down a little to clear the wires.

  

 Dan Hopper

 RV-7A about 200 hours

  

  [quote][b]

ghinman(at)mts.net
Guest

Posted: Fri Dec 29, 2006 9:49 am Post subject: engine baffle safety wire

My engine baffles were installed long ago, but I never put in the 

safety wire on the underside of the cylinders that is supposed to pull 

the lower ends of the baffles tight around the cooling fins.  I just 

stretched a string across there today and it is clear that the safety 

wire would rub against one of the oil return lines.  It's the same story 

on both sides of the engine.



    I guess I could extend the little flange of the baffle to reposition 

the safety wire attach point lower, or I could rivet a little bracket of 

some sort to the to the intercylinder baffle to push the wire down.  

(Come to think of it, it would probably wear through anything I put there.)



    Does any one have a tried and true solution to this problem? Or am I 

missing something here?

--

Tom S., RV-6A, wiring

             I had the same problem and replaced two of the aluminum tube

lines,to make room for the wires that hold the baffle



George H. Inman

ghinman(at)mts.net

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