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av8rps(at)tznet.com
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 Posted: Wed Aug 15, 2007 8:08 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Do not fly your Aerocet 1100 floats without reading this carefully first!
Recently I had two of the cross brace cables fail on my Aerocet floats because the nicopress sleeves slipped on the cable, caused by not being crimped properly when manufactured. Needless to say, when you lose the cross bracing on your floats, it's the equivelent of losing the bungee chords and safety cables from a bungee style landing gear. All worked out ok for me, but I fear what may have happened in a different scenario.
So for anyone flying aerocet floats on their Kitfox or Avids, please check your nicopress fittings to make sure they are crimped properly. You will need a nicopress go/no-go gauge to be able to tell if they are good or not (a $6 tool). If in doubt, re-crimp or replace them. Without good crimps your floats will sooner or later fail! And even if you have a lot of landings on your floats (mine had hundreds and hundreds), it's just a matter of time before the floats will collapse in operation. Most likely this will happen when subjected to a higher than average load (in my case it was caused by a very large boat wake).
I have since been told that Aerocet had a service bulletin about this problem, but I wasn't aware of it until after mine failed.
I don't want to see anyone get hurt, especially knowing there is such an easy remedy to the problem.
Paul Seehafer
Kitfox IV-1200 Aerocet Amphibs
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av8rps(at)tznet.com
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| Posted: Wed Aug 15, 2007 9:02 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Do not fly your Aerocet 1100 floats without reading this carefully first!
Recently I had two of the cross brace cables fail on my Aerocet floats because the nicopress sleeves slipped on the cable, caused by not being crimped properly when manufactured. Needless to say, when you lose the cross bracing on your floats, it's the equivelent of losing the bungee chords and safety cables from a bungee style landing gear. All worked out ok for me, but I fear what may have happened in a different scenario.
So for anyone flying aerocet floats on their Kitfox or Avids, please check your nicopress fittings to make sure they are crimped properly. You will need a nicopress go/no-go gauge to be able to tell if they are good or not (a $6 tool). If in doubt, re-crimp or replace them. Without good crimps your floats will sooner or later fail! And even if you have a lot of landings on your floats (mine had hundreds and hundreds), it's just a matter of time before the floats will collapse in operation. Most likely this will happen when subjected to a higher than average load (in my case it was caused by a very large boat wake).
I have since been told that Aerocet had a service bulletin about this problem, but I wasn't aware of it until after mine failed.
I don't want to see anyone get hurt, especially knowing there is such an easy remedy to the problem.
Paul Seehafer
Kitfox IV-1200 Aerocet Amphibs
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kitfoxjunky(at)decisionla
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| Posted: Thu Aug 16, 2007 3:36 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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How do you tell the diff between 1x19 and 7x19 wire?
Gary Walsh
KF IV Anphib 912S
C-GOOT
www.decisionlabs.com/kitfox
do not archive [quote][b]
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av8rps(at)tznet.com
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| Posted: Thu Aug 16, 2007 3:58 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Guy,
I never knew anything about what you are saying here. So thank you for
informing me. I also had a friend tell me he converted to threaded rod like
is used on larger floats. I think that will be the route I will take. I'm
currently checking availability.
For what it's worth, I did test the new cables I made up and they passed the
1200 pound pull test listed for 1/8" wire. But as you say, if I shouldn't
be using this setup, I will convert either to the threaded rod or swage on
different ends.
It's simply amazing what one can learn by sharing information...
Thanks again for the info.
Paul Seehafer
Kitfox IV-1200 912ul Aerocet Amphibs
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akanka(at)kiamichiwb.org
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| Posted: Thu Aug 16, 2007 4:20 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Here's a drawing of the end view many of the cables made today.
John Hart
  1x7 Preformed Stainless Steel Strand Non-Flexible Type 302/304 (1
For straight load applications, in smaller diameters used as fishing leaders and line. In larger diameters it's used for guy wire and messenger strand applications.
 Stainless Steel Miniature Strand and Cable Type 302/304 (12)
All Commercial Grade
 1x19 Preformed Stainless Steel Strand Non-Flexible Type 302/304 (31)
Widely used as standing rigging on sail boats. It is also well suited for push-pull, and guying applications.
Search 31 Items
3x7 Preformed Stainless Steel Aircraft Cable Type 302/304 (2)
 7x7 Preformed Stainless Steel Aircraft Cable Flexible Type 302/304 (23)
For use where extreme flexibility is not necessary. Commonly used in aircraft and automotive controls, It performs highly in a wide range of mechanical application.
 7x19 Preformed Stainless Steel Aircraft Cable Flexible Type 302/304 (22)
Used when flexibility and fatigue are concerns. Aircraft controls, running rigging on sailboats, exercise equipment, winches and garage doors are all common applications.
 6x19 Class Preformed Stainless Steel Wire Rope I.W.R.C.-Type 302/304 (9)
True working wire ropes, extensively in heavy duty shovels, dredges, skidders, applications.
 6x36 Preformed Stainless Steel Wire Rope I.W.R.C.-Type 302/304 (13)
These constructions are used etensively in heavy duty hoisting cranes. Also used in shovels, dredges, skidders, excavators, logging and oil field applications.
 6x42 Non- Preformed Stainless Steel Wire Rope Type 302/304 (14)
 19x7 Preformed Stainless Steel Wire Rope Type 302/304 (
Used when a single line hoisting operation is necessary. Standard equipment on helicopter rescue winch applications.
1x7 Preformed Stainless Steel Strand Type 316 (Extra Corrosion-Resistant) Non-Flexible (7)
For straight load applications, in smaller diameters used as fishing leaders and line. In larger diameters it's used for guy wire and messenger strand applications.
1x19 Preformed Stainless Steel Strand Type 316 (Extra Corrosion-Resistant) (11)
Widely used as standing rigging on sail boats. It is also well suited for push-pull and guying applications.
7x7 Preformed Stainless Steel Cable Type 316 (Extra Corrosion-Resistant) (3)
For use where extreme flexibility is not necessary. Commonly used in aircraft and automotive controls, It performs highly in a wide range of mechanical application.
7x19 Preformed Stainless Steel Cable Type 316 (Extra Corrosion-Resistant) (6)
Used when flexibility and fatigue are concerns. Aircraft controls, running rigging on sailboats, exercise equipment, winches and garage doors are all common applications.
6x19 Class Preformed Stainless Steel Wire Rope I.W.R.C.- Type 316 (Extra Corrosion-Resistant) (9)
True working wire ropes, extensively in heavy duty shovels, dredges, skidders, applications.
 6x37 Class Preformed Stainless Steel Wire Rope I.W.R.C.- Type 316 (Extra Corrosion-Resistant) (13)
These construction are used extensively in heavy duty hoisting crane. Also used in sholves, dredges, skidders, excavators, logging and oil field applications.
7x7 Preformed Stainless Steel Wire Cable Type 305 Non-Magnetic (2)
For use where extreme flexibility is not necessary. Commonly used in aircraft and automotive controls, It performs highly in a wide range of mechanical application.
7x19 Preformed Stainless Steel Cable Type 305 Non-Magnetic (6)
Used when flexibility and fatigue are concerns. Aircraft controls, running rigging on sailboats, exercise equipment, winches and garage doors are all common applications.
6x19 Preformed Stainless Steel Wire Rope I.W.R.C. Type 305 Non-Magnetic (7)
7x7 Monel Cable (11)
7x19 Monel Cable (9)
Original Message-----
From: owner-kitfox-list-server(at)matronics.com [mailto:owner-kitfox-list-server(at)matronics.com]On Behalf Of kitfoxjunky
Sent: Thursday, August 16, 2007 6:34 AM
To: kitfox-list(at)matronics.com
Subject: Re: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!!
[quote]
How do you tell the diff between 1x19 and 7x19 wire?
Gary Walsh
KF IV Anphib 912S
C-GOOT
www.decisionlabs.com/kitfox
do not archive [b]
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Guy Buchanan
Joined: 16 Jul 2006
Posts: 1204
Location: Ramona, CA
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| Posted: Thu Aug 16, 2007 6:22 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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At 05:17 AM 8/16/2007, you wrote:
| Quote: | Here's a drawing of the end view many of the cables made today.
John Hart |
Thanks John, for covering for me. If you don't mind my asking, where did you get this info?
Guy Buchanan
San Diego, CA
K-IV 1200 / 582-C / Warp / 100% done, thanks mostly to Bob Ducar. [quote][b]
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_________________
Guy Buchanan
Deceased K-IV 1200
A glider pilot too. |
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akanka(at)kiamichiwb.org
Guest
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| Posted: Thu Aug 16, 2007 7:37 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Can't remember the website. I just Googled "aircraft cables" and one of the search results had a link to it. Copied and pasted to the email.
John Hart
[quote] --
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av8rps(at)tznet.com
Guest
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| Posted: Mon Aug 20, 2007 6:03 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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From: "Noel Loveys" <noelloveys(at)yahoo.ca>
Paul do you know what the size of the properly crimped fitting is? I don't
have a terminal (go-no go) gauge but I do have several sets of Vernier
calipers.
Noel
*********************
Noel,
Here is what you need to know. A friend had this bulletin saved (which I
didn't even know existed until after my problem). It gives the nicopress
size and procedures.
Paul Seehafer Model IV-1200 912ul Aerocet amphibs
****************************************
SERVICE BULLETIN #41
DATE: September 6, 1994
SUBJECT: Swaged Fittings on the Cross Brace Cables
APPLICABILITY: All Float Equipped Kitfox's
COMPLIANCE: MANDATORY; RESOLVE BEFORE NEXT FLIGHT
FROM: SkyStar Aircraft Engineering Department
A float equipped Kitfox suffered a brace cable failure during a very hard
water landing. The cable failed by pulling through the swaged nico press
sleeve. Since these sleeves are rated for the full breaking strength of the
cable, our investigation focused on the swaging procedure itself.
Before operating your float-equipped Kitfox again, inspect the swaging on
the sleeves of the cross brace cables P/N 66021.000 for proper compression.
The distance across the widest part of the oval in the swaged areas must be
no greater than .340". If you find a sleeve that is improperly swaged and
have access to a swaging tool, you can re-swage the sleeves to the proper
depth. If you do not have a tool available, return the cables to us, and we
will re-swage and return them to you. (Please call Customer Service for a
RMA number before sending your cables to SkyStar for re-swaging). Upon
successful inspection or re-swaging of your cable sleeves, note compliance
with this bulletin in your aircraft logbooks.
If you have any questions regarding this Service Bulletin, call Customer
Service at 208-454-1443.
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akanka(at)kiamichiwb.org
Guest
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| Posted: Mon Aug 20, 2007 9:19 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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AC 43.13-1B, Chapter 7, Paragraph 7-148 has the info on cable swaging. It's
available online at:
http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgAdvisoryCircular.nsf/0/
99c827db9baac81b86256b4500596c4e/$FILE/Chapter%2007.pdf
Just scroll on down to the appropriate paragraph to read it.
John Hart
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Float Flyr
Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland
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| Posted: Mon Aug 20, 2007 2:40 pm Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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What I was looking for was the width of the gauge at the bottom of pg 7-34
Par 7-148 the chart doesn't give the size of the opening for the terminal
gauge .... Paul was able to find a reference to .340in.. I just finished
re-crimping or swaging with a calibrated crimper so now all my crimps are
within .001 in. of the .340. If it was my own tool I would have calibrated
it for a couple of thousandths tighter.
Noel
All that is left is to square the wings with the floats and lockwire the
turnbuckles.
[quote] --
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_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats |
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av8rps(at)tznet.com
Guest
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| Posted: Tue Aug 21, 2007 4:21 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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Noel,
Glad to hear you've done yours. I will sleep better at night now...
Paul Seehafer
(do not archive)
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Float Flyr
Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland
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| Posted: Tue Aug 21, 2007 5:52 am Post subject: ALERT! ANYONE FLYING AEROCET 1100 FLOATS!! |
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I'm just on my way out the door to make the final adjustments to level the
wings again.
Noel
BTW here is a guy on the avid list who is looking for some data for the W&B
of his avid Mk IV. You wouldn't know the location of the Datum or the CG
range?
[quote] --
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_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats |
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