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JonathanMilbank
Joined: 14 Apr 2012
Posts: 391
Location: Aberdeen area
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 Posted: Fri Apr 23, 2021 11:16 am Post subject: CKT exhaust header tube needed, please. |
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Today while approaching to land and after landing, the engine sounded quite a lot different. After removing the cowls, the header tube for right rear #3 cylinder was seen to have cracked circumferentially completely around. Rather than weld the two parts back together and end up finding further cracking due to the weld, I'd rather just replace the tube with one that is whole.
The carburettors are maintained well balanced with a CarbMate electronic balancer and the Airmaster propeller runs nice and smooth as well. This crack has appeared after more than 4 years in service, so I'm not dissatisfied with the CKT product.
Thanks,
Jonathan
G-EIKY Classic tri-gear
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budyerly@msn.com
Joined: 05 Oct 2019
Posts: 288
Location: Florida USA
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| Posted: Fri Apr 23, 2021 5:58 pm Post subject: CKT exhaust header tube needed, please. |
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If you have an older CKT there were some weld issues.
The 912S is a rougher engine and the exhaust system will shake. If the crack was near the spring attachment it is a weld problem.
Another issue is drilling of EGT holes. Stress risers happen.
If the muffler is hitting the frame the down tube can be stressed in bending and crack.
Wrong kinds of springs can be a problem also, but the springs break before the tube normally.
Sometimes we just don't know. Contact Robin at CKT. They will take care of you.
Best Regards,
Bud Yerly
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JonathanMilbank
Joined: 14 Apr 2012
Posts: 391
Location: Aberdeen area
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| Posted: Sat Apr 24, 2021 11:02 am Post subject: Re: CKT exhaust header tube needed, please. |
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Thanks Bud.
After posting this topic yesterday I was emailed by a Scottish based Europa pilot. He has experienced at least one similar crack at the same location on the tube from #3 cylinder. He also sent pictures of cracks on top of his muffler box, which fortunately I haven't yet suffered. Since installation of the CKT exhaust system 4 years ago, my aircraft has done 230 hours airborne and also about 50 hours running on the ground, before the fracture occurred. Not too bad, I think.
If I remember correctly, Kevin Dilks (a UK Rotax engine rebuilder who used to work in the factory in Austria) advised that the 912S engines have a "sweet spot" around 4700 rpm, so in the cruise I generally set my Airmaster propeller control to Manual and reduce engine speed below 5000 rpm, which subjectively makes everything feel considerably less harsh.
Whether other Rotax 912S powered aircraft are achieving more than 200 flight hours before cracks appear in their CKT muffler systems would be interesting to know.
Finally, yes the other pilot and I both had cracks originating near the spring attachment. Thanks again.
Jonathan
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budyerly@msn.com
Joined: 05 Oct 2019
Posts: 288
Location: Florida USA
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| Posted: Sat Apr 24, 2021 12:49 pm Post subject: CKT exhaust header tube needed, please. |
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CKT replaced any problems for me.
Contact CKT with the year group and save time.
Many of the CKT problems were not a result of welds but installation as many folks did not tighten down the exhaust uniformly. It is not rocket science but I am impressed with the problems with the older shakey 912ULS.
Call CKT.
Bud Yerly
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