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Area-51
Joined: 03 May 2021
Posts: 414
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 Posted: Fri Jan 10, 2025 1:06 am Post subject: What did you do with your Europa this week 10/01/25 |
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This week I took 181 up to 4500' over water and started practicing 180 turn-backs; recording data to establish a 100' height turn at 70kt clean and 55kt dirty. Numbers say it is well within the europa's performance envelope of can do...
Pulled the 100hp ULS out of its crate and scrubbed it up ready to replace the 80hp... A new set of spark plug lead caps and a five year rubber change service and it will be ready to bolt in.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Sat Jan 11, 2025 2:06 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Running some Line Maintenance checks today on the ULS using high end laboratory derived tooling... Breakaway torque on the gearbox dog perfect. Crankshaft phase perfect 0,0,0,0... Bore scope and leak down assessment tomorrow before sending off shopping list...
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Mon Jan 13, 2025 5:53 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Just could not help myself... After rolling the motor over and hearing air escaping past the exhaust valves on three cylinders it was thought better to pull the heads off and descale all the plaque than hope it blows out the exhaust on startup... So off came #1 cylinder head and the dental work began... At 1300hrs everything on the valve train measured up as new; zero wear... For some unknown reason the valve stem seals require replacing... this will be a really nice motor when the scrub up is all done.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Tue Jan 14, 2025 1:05 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Started on #3 head today; getting faster at this.
Have noticed each cylinder so far only has two of four stud o'rings fitted. Weird. Maybe a drunk factory worker, or the assembly automation failed?
The hydraulic lifters are showing zero signs of wear and are 915iS spec components - 854097
I am starting to think the Rotax 9xx motors can really benefit with a cylinder head service every 1000hrs; will extend exhaust valve and seat life well over TBO.
Will begin on the opposite bank tomorrow. Expecting this unit will finish measuring up with zero wear and run just well as a Zero time unit.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Tue Jan 14, 2025 2:25 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Its important to investigate anomalies. First stop was the Heavy Maintenance Manual where a reference to SI-912-019 was presented... And yes, there is only two studs on each barrel that require an o'ring... Ok 🤷🏽♂️...
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Wed Jan 15, 2025 4:11 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Three done; one more to go... All the exhaust valves are displaying pitting on the seat face... Lots of soft loose crud in this cylinder; gets under the valve seat and causes compression loss when burping; gets blown out on startup; caused by leaking inlet valve stem seals.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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erichdtrombley(at)juno.co
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| Posted: Wed Jan 15, 2025 2:41 pm Post subject: What did you do with your Europa this week 10/01/25 |
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What is process for cleaning up the components: pistons, heads, etc?They look brand new!
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Steven Dumesny
Joined: 28 Dec 2023
Posts: 1
Location: Bendigo
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| Posted: Thu Jan 16, 2025 12:02 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Totally agree with Erich what a great clean up job.
Also I don't ever recall seeing such pitting on an exhaust valve seat in any application, it looks like a chemical reaction?
After reading Mike Busch on engines, I plan to use a bore scope every 100 hours, it should pick up these signs earlier, and I can review images against previous services.
"What I did with my Europa today" was had an experienced Europa builder visit and we went over mine, it was great day and I learnt a lot and have a few new tasks.
Thank you for your images in this post.
Best regards
Steve[/quote]
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Thu Jan 16, 2025 2:39 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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Job done; my fingers are sore again... ready to box up swap out the 80hp.
This unit scrubbed up great in the end; as good as new, with 700hrs and 4years TBO remaining. Now just have to replace the few throttle arms and spark plug caps I raided off a while back for the 80hp in 181.
What was learnt through this process:
The 912 ULS-S2 can benefit from periodic checking and resetting of the cylinder head nuts. At 1300hrs 90% of the cylinder studs were loose in their anchor. Some head nuts were returning just 10nm upon undoing.
The rotax 912ULS-S2 will benefit greatly with a cylinder head service at 1000hrs. Which will prevent the exhaust valves having to be binned at 2000hrs TBO, and return the unit to full compression.
Inlet valve stem seals provide inadequate sealing of oil ingress into the inlet port at 1300hrs, causing carbon build up upon the inlet valve and combustion chamber. The symptom of this is seen via low compression on one cylinder during burping as loose bits get trapped under the valve seat. It blows out upon startup but is indicative inlet valve stem seals are failing.
Rear two cylinders of the 912 ULS-S2 run hotter than the front two cylinders. This shows up as minor evidence of detonation erosion on the piston crown and combustion chamber.
For reasons unknown #4 cylinder has had a Sodium "Inlet" Valve fitted.
All four exhaust valves exhibited pitted seats (same as recent 914 job) indicating either hot lean mixtures or acid chemical erosion. The valves are softer than the seats.
The pistons crowns in the 912 are very soft material. A head nut dropped from the barrel stud and fell onto the crown leaving a small indentation; very soft material.
Now that You have read all that nominal stuff I can discuss cleaning methods...
Firstly you will need "high end laboratory tools" like in the attached pictures. Secondly, expect to end the task with really sore fingers by the end from using some of the high end laboratory equipment. The secret to achieving the look achieved is knowing what materials to use; I will go on...
Ultrasonic cleaning bin; I have 5L and 25L units... This is great, but not that great for alloy motor bits; darkens the metal. I need to try sewing machine oil or sulphuric acid and see what the results are. So caustic alkaline fluids are no good for zinc, or zinc alloys.
Scotch pad; industrial grade "grey"; available in a roll at your local paint panel trade supplier... I use this with diluted sugar soap to "finish" clean everything before spray and wipe off with Wurth Rostoff. You will have tired and sore fingers afterwards if you scrub an entire engine.
Brass brush... used to descale corrosion off the engine exterior.
Tooth brush... used to scrub exterior of engine
Stainless brush... used to scrub bits i should be using the brass brush for.
215 or 225 Aluminium sheet. I use this to create some of the high end laboratory equipment. It is used to scrape off the piston crown, head ports, combustion chambers and cylinder wall, and is softer than the piston crown. The edges need to be kept dressed as you work scraping off the crap. You will have sore fingers by the end from scraping... Any piece of metal softer than the piston crown will do the job but you will struggle with lead; mercury would be totally useless though...
Threaded brass pipe. I use this on the exhaust valve stem as a rasp to get the tough shit off quickly.
A piece of flat 0.125" 2030 carbon steel. I use this on the exhaust valve to scrape off the really tough shit.
An oyster shucker. I use this to get the "nothing else will budge it" stuff out of the exhaust port. Its a delicate light handed job because the oyster shucker is hardened steel and will ruin a valve seat and slice through a finger instantly without taking any prisoners.
A piece of TIG welding rod, hammered flat and bent 90deg at one end. This is one of my favourite tools and is used to extract hydraulic lifters to check their face condition.
(When lifting the cylinder barrels you may notice three numbers felt tipped onto the barrel; record these numbers. They are your bore dimensions taken at the factory during engine assembly)
3D printer. Used to print the valve spring compressor.
A vacuum cleaner with a high end laboratory attachment such as repurposed piece of washing machine drainage pipe. Used to extract all the crap from the cylinder and ring lands, and valve ports as you go and keeps the work area clean. Wife will scream and be unhappy for a while, but its only momentary...
Air compressor. To blow out any thread bores before bolting up.
(x4) 2" sections of 3/8 fuel hose.. I use this to seal off the cylinder studs and hold the barrels in place as I work. Screw down two head nuts and you can roll the motor over while head is off. They can be fun to remove afterwards; i use pointed pliers to lift them up and off.
Wurth Rostoff... I use this to wash off the scotch brite residue when cleaning completed. I also skirt a bit into the valve port together with some oil when lapping in the valves. I use a cordless drill on the top of valve stem; much quicker than old timer method.
Each head takes about four hours to process. You will have sore fingers by about midway through the second cylinder onwards.
When torquing down the cylinder heads follow the book method, 10nm +180deg.. I could not achieve symmetrical torque across the head bolts without feeling one or two studs were going to pull out of their anchor.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?Europa-List |
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Area-51
Joined: 03 May 2021
Posts: 414
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| Posted: Thu Jan 16, 2025 5:06 am Post subject: Re: What did you do with your Europa this week 10/01/25 |
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[quote="Steven Dumesny"]Totally agree with Erich what a great clean up job.
Also I don't ever recall seeing such pitting on an exhaust valve seat in any application, it looks like a chemical reaction?
After reading Mike Busch on engines, [u]I plan to use a bore scope every 100 hours[/u], it should pick up these signs earlier, and I can review images against previous services.
Steve[/quote][/quote]
Found bore scope to be totally useless; except for normal looking crowns and honing marks couldn't see s;&(at)... hence listen to my better judgement telling me to pull the heads off and scrutinise things properly on an unfamiliar unit.
Lifting the barrels also allows inspection with mirror beneath the piston crowns to confirm any excessive long term running temperature issues. Also allows visual of the camshaft condition.
Final note on descale and cleaning... practice on some scrap components first... The higher quality things in combustion chamber are polished to the less crud they attract over time. High gloss valves chambers and crowns will generally just wipe clean with a cotton rag and some diesel.
If you drop a valve on the concrete during your activities the valve goes into the bin and you replace it without second thoughts.
| | - The Matronics Europa-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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