Lycoming 0-235 L2C

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Jan 30, 2019 1:18 pm

Starting on cleaning up the exhaust pipes , but ended up cleaning much more.
wow..just a little elbow grease.
.
Gotta Fly...
.
Attachments
Intake and Exhaust (1).JPG
Intake and Exhaust (4).JPG
Intake and Exhaust (3).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Sun Feb 24, 2019 2:20 pm

Hey Guys,
I made a new "Cap" for the Fuel Pump I removed.
.
Others I had seen were thicker.
I was removing the Vacuum pump and needed to cap it, I figured this was a good time to make a better one to plug the fuel pump hole.
I cut them from scrap pieces I save...

The smooth side went toward sealing the hole...
.
Gotta Fly...
Attachments
Lycoming -caps (1).JPG
Lycoming -caps (4).JPG
Lycoming -caps (6).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Feb 27, 2019 3:37 pm

.
Still waiting to hear about my EGT system I ordered,
I'm glad they hadn't shipped it.... cause I wanted to change it from clamp-on to the bayonet style .
.meanwhile , looking it over for baffling , I saw the airflow restricted by casting that should have been cleaned better.
So I went over all four heads.
This area seems to NEED good airflow, it's next to the exhaust valve and spark plug.
it took a long time to hand file all the casting crap...
.
Gotta Fly...
Attachments
2019 cleaning up casting  (1).JPG
2019 cleaning up casting  (3).JPG
2019 cleaning up casting  (2).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Fri Mar 01, 2019 6:03 pm

I got the Wool I ordered.
100% natural wool
It can be beat back with a flame, but it won't light on fire.
I sprayed it with the filter oil.
It's holding the oil.
.
I needed to put the cowl together for measurements...(Baffle babble here)
.
Gotta Fly...
.
PS After reading this , it dawned on me... The oil I saw leaking...a few drips on the cowl...was from this air filter
I thought I was going to have to inspect my brake lines...
Attachments
2019 air intake (1).JPG
2019 air intake (2).JPG
2019 air intake (7).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Sun Mar 10, 2019 2:52 pm

Baffling...
Attachments
2019 Baffling (1).JPG
2019 Baffling (3).JPG
2019 Baffling (5).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Mar 11, 2019 6:56 am

Baffling...
The front/left of the engine seems to be void of any attachment points to support the baffling.
.
My plan was... WAS...Remove the starter...Take the front left "STUD" out...
The hole could be "Tapped" the rest of the way , Which would give me over 1/2" of threads to screw something into it.
No Joy... I tried to take it out. But I was at the point of Damaging something to get it to turn...So...Plan B
.
I use .032 Chromoly plate...a couple Weld-nuts...
I used a thick "heat sink"...I pre-heat with a propane torch, Leave it until it's cold.
When I put the plate on the starter base , I changed the lock washers to star washers.
which were half as thick.
.
Now, I have an attach point for the Baffling over the front of the engine,and a post support for baffle base/bottom
and with the holes I drilled into the plate I can put a cross support on the baffle .( a triangle )
The intake baffle on the left side is the biggest. a Truss/cross brace will be needed to help Engine shake.
Normal operating is fine. It's that "ROCK" when starting or shutting down that needs support.

Gotta Fly...
,
Attachments
2019 Baffling (6).JPG
2019 Baffling (7).JPG
2019 Baffling (8).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Mar 11, 2019 4:53 pm

Side pieces are rough...
and more paper will be harmed.
.
Gotta Fly...
.
Attachments
2019 Baffling (13).JPG
2019 Baffling (10).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Mar 13, 2019 12:57 pm

Less Baffling
.
With the cowl in place, I made some markers to show me the height...
Or what height it doesn't have...
The Datum on the Buttercup is 1/2" higher than a Tailwind...and closer to the cowl

Front, right of the engine is only 5/8" from the cowl... THAT'S gonna leave a mark.
Oh well...

It looks like my next step will be to make the front bracket.
I need more aluminum.
.
Gotta Fly...
.
hmmm, i could "slit"the cowl and let it flex if I have to...
Attachments
2019 Baffling (14).JPG
2019 Baffling (16).JPG
2019 Baffling (17).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Mar 21, 2019 10:59 am

.
Baffling conversation followed by pictures...
.
Gotta Fly...
.
I've never had one of those "contour" tools.
They don't cost much...
I wish the tension could be adjusted...loosened for "fit" and tightened more to transfer the contour.
(Great...another tool mod)
Attachments
2019 Baffling (18).JPG
2019 Baffling (19).JPG
2019 Baffling (20).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Mar 21, 2019 1:13 pm

.
The alternator bracket can still be mounted where the chromoly spacer is used.(including the brackets "Jog" )
I replaced the bolt with a "Stud", it makes it easier for assembly in the tight area.
.
Gotta Fly...
.
Attachments
2019 Baffling (22).JPG
2019 Baffling (24).JPG
2019 Baffling (25).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Mar 21, 2019 1:19 pm

Getting the plenum pieces closer
Attachments
2019 Baffling (26).JPG
2019 Baffling (27).JPG
2019 Baffling (28).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Mar 27, 2019 8:47 am

.
The gap has a piece of fuel line...
It will have a heavier duty hose on final.
It does two things...
Dampens shock...
Holds the bolt during assembly in a tight area.
I'll need to safety wire the bolt
.
Note... My seal is shit... (ok, maybe just crappy)
I HAD a nice fit... But in order to take it in and out...
the shape changed...
My plan has always been to get it close enough to use a rubber/silicone type seal...
I'm also thinking about a thick wool felt seal in places...maybe with leather.
yes...it's baffling
.
Gotta Fly...
.
Attachments
2019 Baffling (31).JPG
2019 Baffling (29).JPG
2019 Baffling (30).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Jul 04, 2019 12:45 pm

.
Building the back wall...
I have a start , forming cardboard it's giving me stretch out dimensions.
I need to Tape more cardboard to it...Then try a one piece cardboard.
I still haven't picked up another piece of aluminum
.
This ain't the greatest cardboard for doing this... I need better stuff for the transfer to one piece of paper
One that will be "formed" with the Brake... Crisp lines.
.
Gotta Fly...
Attachments
2019 Baffling (34).JPG
2019 Baffling (35).JPG
2019 Baffling (36).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
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Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Jul 08, 2019 5:38 am

.
I made a solid contact in a tight/awkward area , Using 1/4" -.035 wall Chromoly tube.
later I might weaken the Cyl head connection for heat expansion (lighting holes)
.
and still having FUN with cardboard ...with a little glue , the toothpicks will mark out a tighter profile

Gotta Fly ...
Attachments
2019 Baffling (45).JPG
2019 Baffling (43).JPG
2019 Baffling (41).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Jul 11, 2019 3:52 am

.
Paper mock-up ...
I used some bailing wire to make staples for holding the added paper to the baffling shape.
This back wall will have to be more than one piece for a tight seal.
Gotta Fly...
Attachments
2019 Baffling (49).JPG
2019 Baffling (51).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 902
Joined: Sat Jan 01, 2005 1:23 pm
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