Lycoming 0-235 L2C

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Sat Nov 23, 2019 10:43 am

.
Other Side...

Lemme Splain...
This has a TIGHT squeeze around the Cyl and Dynafocal mount.
My solution...
Two piece...
The outer baffle is Riveted to the Main Cross piece.
The inner baffle also plugs air on the main cross over piece...

The inner baffle piece...It uses existing threads to help lock in place...
It's cornered by the Cross over piece and the Cyl...
But it could "Tilt" and loose the good air seal.
One rivet... Not holding anything... CLICKS behind the baffle plate/on the cross over piece as it's put in place during assembly.

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My plan is to keep it very light and simple..
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Gotta Fly...
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Attachments
2019 Baffling (133).JPG
2019 Baffling (130).JPG
2019 Baffling (131).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 » Sat Nov 23, 2019 10:48 am

Hmmm,
Worked my way around to the last section before starting on the cover.
.
Here's the start of the paper mock-up...

Gotta Fly...

PS The Magnets are holding the paper mock-up in place because it's all on a steel table top.
The magnets work THROUGH the aluminum...
Attachments
2019 Baffling (134).JPG
2019 Baffling (135).JPG
2019 Baffling (132).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 Dec 06, 2019 12:10 pm

I found Dzus fasteners at Aircorps Aviation...
I can drive by while I'm in town..
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I made a drill guide from hard banding material.
.
Here's a view of the lower Plenum parts.
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I need to make the cover now.
.
Gotta Fly...
Attachments
2019 Baffling (140).JPG
2019 Baffling (141).JPG
2019 Baffling (143).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 Dec 06, 2019 12:17 pm

Hey Guys,
The weight of these lower Plenum pieces comes to 2 lbs 4 ounces
It's strong and comes apart easy.

Gotta Fly...
.
Attachments
2019 Baffling (144).JPG
2019 Baffling (145).JPG
2019 Baffling (147).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Jan 06, 2020 8:22 am

.
Chad , my Stepson passed away in his sleep , Four days after two surgeries...
I've went out to the shop everyday for the past month...Start a fire...Warm it up... But unable to do anything other than some cleaning.
His Muscles have been weakening more this last year.
I would bring him parts that I made...like a show & Tell.
I was about to bring in the Baffling pieces and put it together on his bed.
He liked the WWII Aircraft...

He was dealt a Shit Life... I am happy he's finally FREE.
But still missing him.

Soon... I will be back to work on Mystical Madness.

Gotta Fly...
.
.
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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Tue Feb 18, 2020 6:28 pm

.
I cleared the area for work...
I'm still trimming the original Plenum cover (paper prototype) I made.
I had a long time away , I need to get familiar with what I was doing.
I will take a picture later and edit this post...

Just thought I'd let some of you know I'm moving forward

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

Ok, catching up with pictures in the camera ...

I'm building another edge to secure the cover ,
Peter and Paul will work on the crooked rear bends for a straight line .

Gotta Fly...
.
Tip fer the Day .... Polishing can get you MORE HP
Just look at the extra CYLINDER in the picture ... Vrooom
.
.
Attachments
2019 Baffling (148).JPG
2019 Baffling (149).JPG
2019 Baffling (150).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Feb 19, 2020 1:09 pm

This is where the beginning began .

A few clips , a few patches ...
My plan will be to leave extra overlap in the front areas for a better trim.....Ah....less chance of a mistake after shaping the cover in that area.
There is no plan , I will take what it gives me ....


.
Gotta Fly...

As I left more aluminum material for better final trim...it gets in the way of shaping .
Mostly the front area , so that was a balance of shape , trim , repeat ...I snuck up on it.
( it didn't lay like this sheet of paper )
Attachments
2019 Baffling (152).JPG
2019 Baffling (153).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Feb 20, 2020 4:08 pm

.
Moron the English Wheel ....get it ?

Moron this later , it's big ...giving me room for trimming after the shaping settles

Gotta Fly...
Attachments
2019 Baffling (155).JPG
2019 Baffling (156).JPG
2019 Baffling (157).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Sat Feb 22, 2020 2:33 pm

pix

Gotta Fly...
Attachments
2019 Baffling (158).JPG
2019 Baffling (160).JPG
2019 Baffling (165).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Sat Feb 22, 2020 2:48 pm

pix

Gotta Fly...
Attachments
2019 Baffling (161).JPG
2019 Baffling (162).JPG
2019 Baffling (163).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Feb 24, 2020 3:09 pm

.
Couple things here , I was able to get a better fit cutting the cover,
by re-assembling on the table .

My lightweight baffle support is wood in a fuel line ...
.
Gotta Fly...
Attachments
2019 Baffling (166).JPG
2019 Baffling (167).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: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Feb 24, 2020 3:29 pm

Moron an English Wheel
My goal is to get the cover to sit CLOSE to its shape without a lot of stress .
Later , heat will relax it .

I don't need a Dzuz at every cleco....
I plan on using some as location points with a stud,
save Dzus, save weigh

Its close , needs finer details now ...you know ...the HARD STUFF .

Gotta Fly...
Attachments
2019 Baffling (168).JPG
2019 Baffling (169).JPG
2019 Baffling (170).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Feb 27, 2020 12:22 pm

It's harder to shape with extra material ...
As the shape gets closer , more material is removed ...repeat
Baby steps ...

My original lines to "cut" still look close.
but in this case the extra material helped , and wasn't in the way .
I'm still sneaking up on it .
.
Gotta Fly...

PS The cover is laying in place with two of the top clecos...it is a close match
Attachments
2019 Baffling (171).JPG
2019 Baffling (173).JPG
2019 Baffling (174).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Tue Mar 03, 2020 1:16 pm

Some of the last border around the lower baffle pieces to finish the seal on the cover plate.

I ordered 20 more Dzus sets from Aircorps Aviation .

I'm planning 14 on the Plenum Cover
.
Gotta Fly...

They told me A Couple weeks for the Dzus, I wasn't in a hurry .
After the two weeks went by I stopped in to pick them up .
No Joy , and he didn't plan to order them soon.
??????????????????
I explained that they ADVERTISE these parts ,
Which he replied , they should take it off the Web site

WTF

I ordered them from WICKS today.
Some pieces will need a week ,
I also ordered SMALLER Dzus for other areas inside the Cabin
WTF
After a couple weeks , I called , Hmmm
They could see the order , just couldn't find the paperwork ...
But , the price is more now ..........ok
A week later , no charge on my card means that it hasn't been shipped yet.
I found something here:
https://www.racecraft.com/5-dzus-fasten ... 8_594_595/
I ordered 20 sets of #5 , they shipped the same day .
I cancelled my order from Wicks
Attachments
2019 Baffling (175).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 985
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

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