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Ultrastar Update

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jb92563

Joined: 23 Mar 2007
Posts: 314
Location: Southern California

Posted: Mon Feb 04, 2008 2:31 pm Post subject: Ultrastar Update

Put my UltraStar together in the driveway on Saturday and made a list of the AN- nuts and bolts I still require to replace all the important assembly bits and pieces. 



No point in trusting my life to old hardware for the sake of 20 bucks.



I also fired up the Cuyuna UL-202 and warmed it up....then took it gradually to full power with the wheels chocked, and me standing there holding the thing back while playing the throttle......crikey!!!



This thing puts out a LOT more thrust than I ever imagined.



Blew the surface of my sand/gravel driveway back about 30'.



I'm sure I won't be disappointed with the take off performance!



I did however notice that it sounded more "Synced" when backed off a bit from full throttle....is that normal?



I need to get the 2nd CHT installed so I can see what is going on with that.



Ran it at full throttle for a few minutes and observed about 1425 EGT and 420 CHT. Not sure what normal would be....any ideas?



I also noticed that my patches are glossier and a different yellow in broad daylight than the original.....oh well...its just an ugly duck now I guess, but at least the patches are good and solid.



I'll fire of some pics tommorow...unfortunately my battery died while making a movie of this beast roaring away at full throttle.



Also found out that my fiber glass fuel tank holds 15 gallons....ooops...not cool for a part 103....I plan on permanentley installing a down pipe in the tank filler cap that will effectively limit my fuel capacity to 5 Gallons. 



Need to recalibrate my fuel sender as well for the new limited fuel level range.



As soon as it warms and dries up a bit here I'll be taking to out to El Mirage dry Lake for some test flights....perhaps a month from now.



Looking forward to getting in the air with her finally. Hope they don't test those Predator RPV's on weekends as the dry lake is about a mile from the Predator testing base near Edwards AFB.....uh....maybe I wasn't supose to tell that part...

_________________
Ray

Kolb UltraStar (Cuyuna UL-202)
Moni MotorGlider
Schreder HP-11 Glider
Grob 109 Motorglider

Do Not Archive

Dana

Joined: 13 Dec 2007
Posts: 1047
Location: Connecticut, USA

Posted: Mon Feb 04, 2008 3:05 pm Post subject: Ultrastar Update

At 05:31 PM 2/4/2008, jb92563 wrote:



 	  Quote: 	
		  Ran it at full throttle for a few minutes and observed about 1425 EGT and 

420 CHT. Not sure what normal would be....any ideas?


	


Max CHT should be 400°F

Max EGT should be 1275°F

Best power EGT is  1200°F



The EGT probe is supposed to be 1½" from the manifold flange gasket.  You 

really only need gauges in the #1 (rear) cylinder (unless you're running 

dual carbs) as that one runs hotter.  Mine is located farther away, where 

the two pipes join, and reads higher... but the CHT is lower, the engine 

runs OK and the plugs look fine so I tend to distrust the gauge.



-Dana

--

  To Be Old And Wise You Must First Be Young And Stupid

jb92563

Joined: 23 Mar 2007
Posts: 314
Location: Southern California

Posted: Mon Feb 04, 2008 4:25 pm Post subject: Re: Ultrastar Update

I better try that again and double check the numbers as mine seem high, but I was recalling them from what I remembered a couple days ago so perhaps I remembered them wrong.



Are those numbers the Max from Cuyuna manual, or from your own engine?



I guess looking at the plugs should give an idea to what is happening as well.



I wonder if a couple minutes running is enough to get an indication on the plugs?



I have a single carb setup....still need to add a KFN filter.



EGT probe is just before the Y junction on the rear cylinder exhaust.



CHT is on the rear cylinder as well

_________________
Ray

Kolb UltraStar (Cuyuna UL-202)
Moni MotorGlider
Schreder HP-11 Glider
Grob 109 Motorglider

Do Not Archive

Dana

Joined: 13 Dec 2007
Posts: 1047
Location: Connecticut, USA

Posted: Tue Feb 05, 2008 4:13 am Post subject: Ultrastar Update

At 07:25 PM 2/4/2008, jb92563 wrote:



 	  Quote: 	
		  Are those numbers the Max from Cuyuna manual, or from your own engine?



I guess looking at the plugs should give an idea to what is happening as well.



I wonder if a couple minutes running is enough to get an indication on the 

plugs?


	


Ray, the numbers I gave are from the Cuyuna manual.  I don't know how much 

running time is necessary to read the plugs, but it can't hurt to have a 

look.  Also check what main jet is in your carb, and where the needle is; 

you might need to go bigger and/or move the needle clip down.



-Dana



--

  "Very funny, Scotty.  Now beam down my clothes."

jb92563

Joined: 23 Mar 2007
Posts: 314
Location: Southern California

Posted: Tue Feb 05, 2008 7:37 am Post subject: Re: Ultrastar Update

Sounds like I am running to lean if those numbers are right.



Not sure how to tune it for richer, would the needle clip go in the next lower notch to make it more rich?



Or do I change needles to make it richer.....lower needle number is richer?



I'll take a look and see what needle number I am running tonight.



Dana, what needle number are you running?



Are you using a filter on your carb?

_________________
Ray

Kolb UltraStar (Cuyuna UL-202)
Moni MotorGlider
Schreder HP-11 Glider
Grob 109 Motorglider

Do Not Archive

John Hauck

Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

Posted: Tue Feb 05, 2008 8:04 am Post subject: Ultrastar Update

Ray:



Are you running the correct prop pitch?



Two stroke tuning in an airplane is based on correct prop loading as the 

number one item.  If it is incorrect, everything on down the line, jets, 

needles, and plugs, with also be incorrect.



I find the best way to get an unknown engine back in line is put everything 

in the carb back where it belongs, and insure jetting and needles are 

correct size.



Also insure the spark plug is the correct heat range.



Insure the correct prop and pitch is installed.  For a Cuyuna ULII02, I 

believe that would have been a Jim Culver 50X30.  That was a perfect prop 

for the US with ULII02.



Hope you all are operating those engines with air filters.



john h

mkIII

 > Sounds like I am running to lean if those numbers are right.



 > Are you using a filter on your carb?

 	  Quote: 	
		  

 --------

 Ray

_________________
John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama

herbgh(at)nctc.com
Guest

Posted: Tue Feb 05, 2008 2:39 pm Post subject: Ultrastar Update

I seem to recall that the Ul202 engine was succeptible to case 

leaks..Needed re torqueing once in a while.. A very old engine model 

at any rate..15 years old or older?   Herb

At 09:37 AM 2/5/2008, you wrote:

 	  Quote: 	
		  



Sounds like I am running to lean if those numbers are right.



Not sure how to tune it for richer, would the needle clip go in the 

next lower notch to make it more rich?



Or do I change needles to make it richer.....lower needle number is richer?



I'll take a look and see what needle number I am running tonight.



Dana, what needle number are you running?



Are you using a filter on your carb?



--------

Ray



Kolb UltraStar (Cuyuna UL-202)

Moni MotorGlider

Schreder HP-11 Glider

Riverside County, CA



Do Not Archive





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http://forums.matronics.com/viewtopic.php?p=162522#162522

John Hauck

Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

Posted: Tue Feb 05, 2008 2:53 pm Post subject: Ultrastar Update

> I seem to recall that the Ul202 engine was succeptible to case

 	  Quote: 	
		   leaks..Needed re torqueing once in a while.. A very old engine model at 

 any rate..15 years old or older?   Herb


	




Herb:



The ULII02 was a good engine.  Had CDI ign, which was much easier to 

maintain than the point ign Rotax's.



If one did not retorque the cylinders every 100 hours or more, they were 

prone to leak at the cylinder base gasket.  This was probably caused by the 

small amount of metal that remained after the engine cases were lightened 

from the 430 to the ULII02.  In an US the engine had to be dropped from the 

engine mount to get at the bolts to torque them.  Because of the extra work 

involved, most of us would fly them until they started leaking, then end up 

replacing cyl base gaskets and head gaskets.



Never had any big problems with the ULII02, but was plagued with little ones 

that were annoying and would occasionally put one on the ground.  It was all 

a big learning curve, getting out of turbine powered helicopters that had 

lots of folks and lots of money available for parts and repairs, into a 

little two stroke that had to be maintained by a guy anxious to fly more 

than anxious to spend all time on the ground fixing stuff.



john h

mkIII

_________________
John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama

herbgh(at)nctc.com
Guest

Posted: Tue Feb 05, 2008 3:32 pm Post subject: Ultrastar Update

John

   Yeah!  I am old and good also...

     I had a UL202 on the US that I had... Very surprised at the ease 

of starting.. Nearly fell backward, expecting to have to pull and 

pull and pull .. Started just about the time I pulled the rope a foot 

or so.. Ran strong.   Herb

At 04:50 PM 2/5/2008, you wrote:

 	  Quote: 	

 > I seem to recall that the Ul202 engine was succeptible to case

>leaks..Needed re torqueing once in a while.. A very old engine 

>model at any rate..15 years old or older?   Herb

Herb:

The ULII02 was a good engine.  Had CDI ign, which was much easier to 

maintain than the point ign Rotax's.

If one did not retorque the cylinders every 100 hours or more, they 

were prone to leak at the cylinder base gasket.  This was probably 

caused by the small amount of metal that remained after the engine 

cases were lightened from the 430 to the ULII02.  In an US the 

engine had to be dropped from the engine mount to get at the bolts 

to torque them.  Because of the extra work involved, most of us 

would fly them until they started leaking, then end up replacing cyl 

base gaskets and head gaskets.

Never had any big problems with the ULII02, but was plagued with 

little ones that were annoying and would occasionally put one on the 

ground.  It was all a big learning curve, getting out of turbine 

powered helicopters that had lots of folks and lots of money 

available for parts and repairs, into a little two stroke that had 

to be maintained by a guy anxious to fly more than anxious to spend 

all time on the ground fixing stuff.

john h

mkIII

Dana

Joined: 13 Dec 2007
Posts: 1047
Location: Connecticut, USA

Posted: Tue Feb 05, 2008 3:51 pm Post subject: Ultrastar Update

At 10:37 AM 2/5/2008, jb92563 wrote:



  	  Quote: 	
		  Sounds like I am running to lean if those numbers are right.

 Not sure how to tune it for richer, would the needle clip go in the next lower notch to make it more rich?

 Or do I change needles to make it richer.....lower needle number is richer?

 I'll take a look and see what needle number I am running tonight.

 Dana, what needle number are you running?

 Are you using a filter on your carb? 	


 Ray, yes, it sounds like it's lean.  Moving the needle clip down makes the needle go up, which makes it richer... but only in the midrange.  I don't know what needle number I have; I don't think many people change them.  Full throttle mixture is controlled by the main jet, which _does_ need to be changed according to the seasons or altitude:



 ULII-02, Cuyuna exhaust, Mikuni VM32 carburetor

 Altitude        

 8000            250     240     230     220     210

 6000            270     260     250     240     230

 4000            290     280     270     260     250

 2000            310     300     290     280     270

 Sea Level       330     320     310     300     290

 Temp. °F        0-20°   20-40°  40-60°  60-80°  80-100°



 Mine had a 300 main jet, which I changed to a 310 for winter flying (below 40° and it's too cold to fly!).  On a couple of hot days last summer, I stuck with the 300 jet (all I had at the time) but I had the needle clip in the top notch.



 -Dana



 

 

 --

  The strongest reason for the people to retain the right to keep and bear arms is, as a last resort, to protect themselves against tyranny in government. - Thomas Jefferson    [quote][b]

jb92563

Joined: 23 Mar 2007
Posts: 314
Location: Southern California

Posted: Tue Feb 05, 2008 10:05 pm Post subject: Re: Ultrastar Update

Good info folk I appreciate all the great feedback.



I'm going to save all that info and check it all out.



I also love the easy starting of the UL-202....a short pull is all it takes once its primed.



In the meantime, here are some pics.

Kolb_2002_0101_000011AA.JPG

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450 Time(s)

Kolb_2002_0101_000108AA.JPG

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426 Time(s)

Kolb_2002_0101_000126AA.JPG

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1.28 MB

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432 Time(s)

_________________
Ray

Kolb UltraStar (Cuyuna UL-202)
Moni MotorGlider
Schreder HP-11 Glider
Grob 109 Motorglider

Do Not Archive

jbhart(at)onlyinternet.ne
Guest

Posted: Wed Feb 06, 2008 6:08 am Post subject: Ultrastar Update

At 10:05 PM 2/5/08 -0800, you wrote:

 	  Quote: 	
		  

In the meantime, here are some pics.




	


Ray,



Looks like your Ultrastar has negative dihedral.  

Should make it a fun aircraft to fly.



Jack B. Hart FF004

Winchester, IN

jb92563

Joined: 23 Mar 2007
Posts: 314
Location: Southern California

Posted: Wed Feb 06, 2008 7:25 am Post subject: Re: Ultrastar Update

I'll double check the dihedral with my laser level once I get the proper bolts, but if there is any, its probably because I used undersized temporary non AN bolts to assemble so I could take an inventory of what I needed to buy.



Thats what resulted in a slight negative dihedral.



Same thing on the elevator hookup as they were noticeably mis-aligned with my temporary undersized bolts.



Actually, having a slight bit of negative dihedral is not a bad thing,  just makes the aircraft more neutrally stable in the roll axis......makes turning more effortless as it will resist rolling out better....no big deal really, and it helps considerably in crosswinds to resist weather-vaning.



Funny thing is that every aircraft I have owned have some V in them as I have a owned 4 V-tails so far,  perhaps the Ultrastar is feeling left out and trying to conform as well

_________________
Ray

Kolb UltraStar (Cuyuna UL-202)
Moni MotorGlider
Schreder HP-11 Glider
Grob 109 Motorglider

Do Not Archive

GeoR38

Joined: 25 Jan 2006
Posts: 60
Location: The Villages, fl

Posted: Sun Feb 10, 2008 7:36 pm Post subject: Ultrastar Update

Who's never won?  Biggest Grammy Award surprises of all time on AOL Music.

  [quote][b]

_________________
George Randolph
Firestar driver, The Villages, fl

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