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Oil cooler thermostat
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Gilles.Thesee(at)ac-greno
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PostPosted: Wed Nov 15, 2006 9:02 am    Post subject: Oil cooler thermostat Reply with quote

Raimo,

Quote:
ALL water cooled engines should also
have water thermostat. That is a matter
of course in cars

The operational conditions are not the same : cars are designed to run
for hours at low speed. They've got plenty of room to install wide and
shallow radiator cores, with huge batteries to run powerful fans. They
don't have weight or aerodynamical limitations (but should).

Quote:
- why not in planes
with water cooled engines also?


Planes are creating a pretty fair breeze of their own. They have weight
and reliability constraints. Designing a proper cooling ducts means
recovering some of the cooling drag, instead of wasting it and adding
fans, by-passes, etc. to try and maintain correct temps.
Drag and weight reduction means improved fuel efficiency, take-off and
climb performance, better cruise, etc...
The cleaner the airplane, the greater the effect of even a small drag
reduction.

Our airplane has a clean and reliable engine installation, with adequate
cooling whatever the conditions. We can always choose our target engine
and oil temps.
No obstructions, no thermostat, extra plumbing, fittings, etc...
Just a good understanding of internal flow, and a well designed duct and
flap.

Regards,
Gilles Thesee
Grenoble, France
http://contrails.free.fr


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josok-e(at)ukolo.fi
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PostPosted: Wed Nov 15, 2006 9:58 am    Post subject: Oil cooler thermostat Reply with quote

Hi Gilles,
Yes we know cars and airplanes are not the same. We know the thread started because there is a returning problem with over cooling in our circumstances. We also know that your airplane is not an Europa and has a perfectly designed cooling system. Europa's have not.

There are several solutions, from redesigning the cowl with intake- our outlet-flaps to simple solutions like thermostats. Thermostats are automatic, install and forget, proved reliable technology. Probably lighter the any flap and it's non-automatic control mechanism. The new thing in this Finnish contribution is the oil/water heat exchanger, that saves the weight of the oil radiator and it's content.

Since the temperatures here vary between +30 and -40 during a normal year here, a pretty fair breeze is not enough to keep temperatures within acceptable limits. I hope you can accept our different point of view.

Kind Regards,

Jos Okhuijsen
Visit - www.EuropaOwners.org


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sidsel.svein(at)oslo.onli
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PostPosted: Wed Nov 15, 2006 11:08 am    Post subject: Oil cooler thermostat Reply with quote

Thank you all very much for the additional input for further reflections.

I am still not 100 pct certain what to do - or how to do it - but I have a
100 pct better basis on which to make a conclusion.

If I were to build the airplane again, I would have studied the Finnish
water/oil heat exchanger solution with great interest. The Rotax dealer in
Sweden sells such heat exchangers, I note.

Our friends in Finland a raised the issue of pre-heating before start in
cold weather. I use the hair dryer-method, with a 1800 w dryer blowing into
the special cooling duct for the 912S. On extra cold days another smaller
dryer blows into the right side cowl opening for extra pre-heating of the
oil tank. When my pre-flight inspection is done and I otherwise have
everything planned and ready for the flight, the engine starts with just a
brief application of choke. Between flights I have a 200 w heater under the
cowl outlet behind the coolers and 2 x 60w light bulbs inside the cockpit,
all with the hope of keeping the worst of the moist winter air out of the
engine compartment and behind the panel.

Best regards,
Svein
LN-SKJ


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raimo.toivio(at)rwm.fi
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PostPosted: Wed Nov 15, 2006 1:01 pm    Post subject: Oil cooler thermostat Reply with quote

Dear Gilles!

Quote:
The operational conditions are not the same : cars are designed to run
for hours at low speed. They've got plenty of room to install wide and
shallow radiator cores, with huge batteries to run powerful fans. They
don't have weight or aerodynamical limitations (but should).

I demand I am able to fly at any speed at any outside temperature
as long as I like (within Europa limits of course).
Like 50 knots (at) -30C 5 hours. Or full power (at) +40C.
If it happens to make me happy.
Just like I do with my cars.
And all modern cars do have strictly weight and aerodynamical limits!
They must be sleek for fuel efficiency and light enough to compensate
all the necessary and "necessary" equipments

In early days there were manual flaps and cowls also in cars.
There were also magnetos, carburrettors, adjustable mixture and
ignition, hand operated turning lights etc. I am happy these are not
reality any more. Some people think grandfatherīs ideas are some kind
of Value and they all must be found in flying apparatus. Thermostat is
not so new idea, but water cooling is (in planes). Why should we start
at the bottom again? Like invent a wheel again.

Who is happy when leaning manually in Cessna? It is always a little
risk and if not, it is bad also. In early days they say there was an engine
man per engine in a plane. Fun? I am alone and would like fly, no
playing games with flaps and being worried is it OK or not.

Think: itīs minus 25C and I have to wait 15 minutes my turn to line up.
My engine will be at ideal temp all the time but how about engine w/o
thermostat? What about long lasting idle glidings - engine w thermostat
will thank you and it get an serial orgasm.

The size of the thermostat is like a babyīs fist and the weight is
about 200 grams. Itīs price is insignificant.

Quote:
No obstructions, no thermostat, extra plumbing, fittings, etc...
Just a good understanding of internal flow, and a well designed duct and
flap.

That is it. The engine inside temperature should be controlable some how.
Flap assembly does the job also so and so but look at the list below:

- it is heavy (thermostat is light weight)
- it is complicated (thermostat is simple)
- it is unic hand work (thermostat is a mass serial product)
- it is hard to install (thermostat is straightforward)
- it tooks space and you have not it too much w Europa (thermostat does not)
- it needs regular service and inspections (thermostat is forgetable)
- it is expensive (thermostat is cheap)
- it is manual and you have one knob more (thermostat is automatic)
- it is not always in ideal position, because it is pilot operated
(thermostat is always in ideal position, no steps)
- when broken, it can happen in closed position and it stays closed
(thermostat stays open when broken but that situation happens
almost never - they are highreliable)
- when starting, cold water is cooling your engine harmly instantly
(when thermostat water is not cooling the engine until necessary)

Hey we all should be experimental men! We can, we have to and
we are allowed to experiment what ever we want (at least here in Finland).

Jos and I are brave men and we have decided to test that sensational equipment:
A WATER THERMOSTAT IN A WATER COOLED ENGINE.
We promise to report later about thermostat but I am sure there is nothing to report exept it works well. It is so obvious. In other case I personally promise
to eat it.

Is nīt that so, Jos?

Ideal Temperature Regards, Raimo
========================

Quote:

Regards,
Gilles Thesee
Grenoble, France
http://contrails.free.fr















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raimo.toivio(at)rwm.fi
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PostPosted: Wed Nov 15, 2006 1:57 pm    Post subject: Oil cooler thermostat Reply with quote

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Gilles.Thesee(at)ac-greno
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PostPosted: Wed Nov 15, 2006 1:57 pm    Post subject: Oil cooler thermostat Reply with quote

Raimo,

Quote:
- it is heavy (thermostat is light weight)
- it is complicated (thermostat is simple)
- it is unic hand work (thermostat is a mass serial product)
- it is hard to install (thermostat is straightforward)
- it tooks space and you have not it too much w Europa (thermostat does not)
- it needs regular service and inspections (thermostat is forgetable)
- it is expensive (thermostat is cheap)
- it is manual and you have one knob more (thermostat is automatic)
- it is not always in ideal position, because it is pilot operated
(thermostat is always in ideal position, no steps)
- when broken, it can happen in closed position and it stays closed
(thermostat stays open when broken but that situation happens
almost never - they are highreliable)
- when starting, cold water is cooling your engine harmly instantly
(when thermostat water is not cooling the engine until necessary)



Everyone here is entitled to express one's technical opinion, and
clearly your are sold on the water thermostat !
I understand your motivations, and wouldn't try to dissuade you. I would
say that you are right on most of the above points concerning the
thermostat.
Like many others, I sure would appreciate any technical feedback on it's
operation.
I only intervened in this topic because I (maybe wrongly) got the
impression that you were asking questions about cooling.

I just hope I too am entitled to express my opinion on cowl flaps, based
on many hours experimenting and flying them, with findings somewhat
different than most of the above points.

Best regards,
Gilles
http://contrails.free.fr


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ami(at)mcfadyean.freeserv
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PostPosted: Wed Nov 15, 2006 3:00 pm    Post subject: Oil cooler thermostat Reply with quote

Probably not much, other than to create a disproportionately large amount of drag. There must be a huge plume of air coming out of these gills that destroys the airflow down the sides of the fuselage.

I had a nice photo of an oil streak on Williams Europa, showing flow reversal just aft of the gills. Conversion of the gills to a rear-facing exit may prove beneficial (to reducing cooling drag), although care needed to ensure fuselage composite not overheated. I have the moulds for such a mod., but never tried it out.

The detailing on Daryl Greenermeyer's Reno Legacy shows the way to go.

Duncan McF
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ptag.dev(at)tiscali.co.uk
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PostPosted: Wed Nov 15, 2006 4:37 pm    Post subject: Oil cooler thermostat Reply with quote

Hi! Duncan.
Thanks for that message. I spoke to Andy Draper today and he said that the gills initially were put in for cooling when parking up, and had been surprised when flying without doors once he put his hand over the port gills and found hot air! This rather substantiates my not having the gills as a Jabiru Cowl.
The Jabiru Carb sits right above the muffler and I had a suitably placed soldering mat on top of the muffler , can’t see why this shouldn’t work for Rotax and leave the gills blocked
Regards
Bob Harrison.
Robt.C.Harrison


-----Original Message-----
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of Duncan & Ami McFadyean
Sent: 15 November 2006 22:56
To: europa-list(at)matronics.com
Subject: Re: Oil cooler thermostat

Probably not much, other than to create a disproportionately large amount of drag. There must be a huge plume of air coming out of these gills that destroys the airflow down the sides of the fuselage.



I had a nice photo of an oil streak on Williams Europa, showing flow reversal just aft of the gills. Conversion of the gills to a rear-facing exit may prove beneficial (to reducing cooling drag), although care needed to ensure fuselage composite not overheated. I have the moulds for such a mod., but never tried it out.



The detailing on Daryl Greenermeyer's Reno Legacy shows the way to go.



Duncan McF
[quote]
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paul.mcallister



Joined: 09 Jan 2006
Posts: 177
Location: Waukesha, WI USA

PostPosted: Wed Nov 15, 2006 4:48 pm    Post subject: Oil cooler thermostat Reply with quote

Hi All,

Actually I have my gills rear ward facing. It wasn't by design, I just made a mistake and I didn't even know until Andy pointed it out to me.

Although I don't have before and after measurements, the underneath of my cowl seems cooler that some other people have reported. I base this on the fact that I don't have any cable ties that melt under the cowl, whereas I have heard many reports from others.

One of these days I must smear a bit of oil around to see what is happening

Paul

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ptag.dev(at)tiscali.co.uk
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PostPosted: Thu Nov 16, 2006 12:04 am    Post subject: Oil cooler thermostat Reply with quote

Hi! Paul/ Duncan.
Thanks for the message below. Even without any gills but with the Jabiru arrangement I had no such thing as cable tie meltdown. The nearest sign I had was some “spirowrap” which ran under the exhaust manifolds. As I said I believe the presence of the gills in flight allows the upper cowl pressure to reduce so discouraging the downward cooling flow. If the gills were added to allow residual cooling after shutdown it would be simpler to open the top access panels immediately on shut down. I have ordered “the fibre glass engine cooling hood” on my engine which should also assist in preventing the heat build up in the cowl top and I expect my intercooler air to assist with cowl top cooling too. I would have expected the Jabiru being fully air cooled to have far more residual heat to dissipate on shutdown anyway and since I didn’t have a problem then I will leave the gills on my new cowls closed, unless I get some more feedback against.
I’ve not had a rattling response on the question
Regards
Bob Harrison G-PTAG


-----Original Message-----
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of Paul McAllister
Sent: 16 November 2006 00:48
To: europa-list(at)matronics.com
Subject: Re: Oil cooler thermostat

Hi All,



Actually I have my gills rear ward facing. It wasn't by design, I just made a mistake and I didn't even know until Andy pointed it out to me.



Although I don't have before and after measurements, the underneath of my cowl seems cooler that some other people have reported. I base this on the fact that I don't have any cable ties that melt under the cowl, whereas I have heard many reports from others.



One of these days I must smear a bit of oil around to see what is happening



Paul



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ami(at)mcfadyean.freeserv
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PostPosted: Thu Nov 16, 2006 3:06 am    Post subject: Oil cooler thermostat Reply with quote

Closing off the gills is likely to result in thermal stress and shorter life of the alternator regulator, if you have it mounted in that region.

A permanent hot air vent (following shutdown) in the top of the cowl can be achieved by leaving out the baffle seals around the top of the carb airbox. However, I have yet to discover whether this also results in flow reversal through the cowl-top NACA duct at high AoA.

I've recently opened up this duct (without the baffle seals and having previously run on under-cowl air) and find that the significant power increase (a good10+% I reckon and an additional 200fpm on climb out) is a bit fickle, depending on flight condition, suggesting variable effectiveness of the duct.

Duncan McF.
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ami(at)mcfadyean.freeserv
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PostPosted: Thu Nov 16, 2006 3:06 am    Post subject: Oil cooler thermostat Reply with quote

Paul,
Does this mean that you cut out the incorrect face on the gills (choice of two faces; one correct, one not)?
You are not unique, there is at least one other around that had this 'mod'.

Duncan McF
do not archive
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raimo.toivio(at)rwm.fi
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PostPosted: Thu Nov 16, 2006 6:08 am    Post subject: Oil cooler thermostat Reply with quote

Gilles

I hope this the Spirit of the Forum:"
"Everyone here is entitled to express one's technical opinion"
So nothing personal. All the responsibility is readerīs not writerīs.
Also everybody can understand this is not pure black or white -case.
I personally trust water thermostat and that is it. Flaps are for you.
Most Rotax flyers fly w/o cowl flaps or thermostats and are happy.

My "salesmanīs comparíson list" was made by IMHO principle.
I know and understand thermostats well but flaps; I have only
mental pictures. Maybe you could list the facts of flaps?

Ideal Temperature Regards, Raimo

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n914va(at)bvunet.net
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PostPosted: Thu Nov 16, 2006 6:59 am    Post subject: Oil cooler thermostat Reply with quote

I would be very inclined to go with a water thermostat, but I have one question. If it fails, does it fail closed or open?

Vaughn
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belinda(at)gloverb.freese
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PostPosted: Thu Nov 16, 2006 8:07 am    Post subject: Oil cooler thermostat Reply with quote

Hi Bob,

Since you know all about my "Flying for Fun" accident already, just a word of WARNING for others reading this thread.

Don't try closing the gills if you fly an NSI Subaru in a Europa. This PFA "Approved" installation, even with the standard gills the cooling to the alternator is wholly inadequate and can kill you. This has now fried 2 alternator bearings out of 10 examples in the U.K. I can't find any U.S examples of such an incident so it looks like a thoroughly home grown U.K. installation problem.

The alternator seizure would be only a minor inconvenience were it not for the fact that the dual drive belts as "Approved" then fill the cockpit with thick smoke before stopping the engine via the braking effect on the crankshaft drive pulley and the "Approved" propeller then goes in to full disk drag freewheeling mode providing an earlier opportunity for a forced landing than you ever bargained for with a descent deck angle of about 20 degrees and rate of 1700ft/min and with the all flying"now no longer flying" tailplane allowing you to slap the stick from stop to stop on the way down as you relearn how to fly the crippled airframe. All this of course negating any amount of practice forced landings you were forced to do before being allowed to test fly the creation yourself and which were so misrepresentative as to have best been avoided completely !!!!!!!!!!!!!!!!!!!

Been there done that got the T-shirt just like Bill Wynne who had it happen first but sadly his incident was never subsequently properly investigated. It will be now though my wreckage is with the AAIB at Farnborough.

I am still trying to find out if "Approved" for regulatory end users means anything other than you are "Approved" to go and be our installation test pilot with a passenger, oh and in case you survive please report any testing we might have overlooked !!!!!!!!!!!!!

Despite the direct question having been twice posed to the PFA, by me and the AAIB so far no cigar!!!!!!!!!!!

Ironically, I just applied for the PFA airworthiness engineer job, which I thought might have even come about because of our near death experience. I just received a response having heard nothing for a fortnight as follows;
" Unfortunately you were not short listed for the initial interviews".
That is despite going and asking if I would be wasting my time preparing a C.V. before hand!

Incedently our Europa callsign was G-BWCV abbreviated to 'CV. Obviously our recent ridiculous incident was not deemed the right sort of 'CV for that particular job.

So look outl for the AAIB report coming out soon if you realy want a case study in how not to do it!!!!!

If anybody thought "Approved" in the regulatory end user context was a verb implying knowledge or understanding and testing to a standard at least minimally fit for purpose like I did, think again.

Like most things these days you end up having to do other peoples jobs for them whilst in the case of the regulators they tie both hands behind your back when you try to do your own.

Regards
Gary McKirdy

[quote] From: R.C.Harrison (ptag.dev(at)tiscali.co.uk)
To: europa-list(at)matronics.com (europa-list(at)matronics.com)
Sent: Wednesday, November 15, 2006 11:43 AM
Subject: RE: Oil cooler thermostat



Hi! Nigel/all
My two pennyworth ....I also tried a cowl exit flap but not to close off. My Jabiru cooling system of course was ALL air cooled and the theory ventured by the Jab dealer and Factory was to extend it into the air stream and create a low pressure area aft of the cooling exit to suck out the hot air..... needless to say it made no improvement whatever. However what I did find was that it was important to maintain top cowl pressure high to promote the mass down flow of air past the engine, I even collected my cabin heating air(when not being used for purpose) and dumped it in the cowl top which also assisted. Since all the high pressure oil cooling air was directed under the sump cooling fins(Rotax oil and water cooling likewise) to leave it "floating" in the lower cowl restrained the downward flow of engine cooling air.
You may ask why am I "rabbitting on" about damn Jabiru's ?.... so to my question:-

What purpose do the Europa "Gills" serve?
Has anyone flown with them blocked off to check the effects?

As it happens, against most advice, I have decided to fit an intercooler on my 914 Turbo which of course has a huge discharge of warm air mostly into the top cowling and I’m not sure it’s the right philosophy to let it exit out the “gills”, with my Jabiru experiences I’m suggesting that to increase the down flow of air, even with water and oil cooling on the engine, it would be best maintaining the top cowl pressure.
I never had any top cowl exits on my Jabiru set up ...all air was discharged out the lower cowl exit plus the lower cowl was "jacked" off the fuselage by approx 1" increasing the discharge annulus considerably.
Any help with these questions would be gratefully received.
I also would have liked to have the Rotax oil flow to its cooler selectable and/or meterable which I achieved on the Jabiru by a hand control valve operated from the P1 Position allowing most flying to be accomplished without the cooler being in circuit. The resultant warm air (even with no oil circulating though the cooler) was a primary source of cabin heat and with the oil cooler in full flow I could fry the passenger, I get the feeling that a number of Europa Rotax owners would dearly like such a facility !

Regards
Bob Harrison G-PTAG (Still prepared to learn!)



-----Original Message-----
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of nigel charles
Sent: 15 November 2006 09:38
To: europa-list(at)matronics.com
Subject: RE: Oil cooler thermostat

--> Europa-List message posted by: "nigel charles" <nwcmc(at)tiscali.co.uk>

Quote:
It is best to place a flap at the exit of the cowl/radiator duct.
Placing an obstruction in the front destroys dynamic pressure. An we

need to recover as much pressure as we can to persuade the air to flow
across the rad core.<

For what its worth I tried a cooler flap at the rear of the radiators.
With it fully closed it cut off nearly all the airflow and it made
little difference to the CHT and oil temperatures.

When I was at Vichy this year I met one of our French owners (sorry I
forgot his name). He has a very clever inlet cowl flap. It is part of
the lower cowl in front of the radiators and has a hinge at the rear of
it. In very hot weather it is lowered below the normal cowl allowing
more cooling air in. In cold weather it is raised impeding airflow to
the radiators. This is all controlled from the cockpit so that inflight
adjustments can be made. From what he told me it works very well.

I appreciate that normally control of cooling air is best done at the
outlet but in this case it seems it is better to use the inlet.

Nigel Charles



Quote:


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PostPosted: Thu Nov 16, 2006 8:38 am    Post subject: Oil cooler thermostat Reply with quote

Vaughn,

I cannot be absolutely sure but NORMALLY
thermostat design itself leaves it fully
open in failure situation.

Who knows ANY broken thermostat in
cars (younger than 10-20 years)?

Problems may occur if the coolant liquid
is NEVER changed.

In cars most people never do it IMHO.
Just like brake fluid, it should be changed
regularly (letīs say once a 1-3 year
to remove moisture and small obstackles etc).

May I suggest you to go some car spare shop,
keep it on your hand and look at it carefully?

Regards, Raimo


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josok-e(at)ukolo.fi
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PostPosted: Thu Nov 16, 2006 10:38 am    Post subject: Oil cooler thermostat Reply with quote

Could it be, that the combination of open gills, bottom cowl opening and entry holes in front creates a pocket of standing air, or pulls air from around the exhaust over the generator or would it not be better to have a designated, more or less defined single entry and exit point? So doing away with the gills all together.
I've asked Andy the same question on his last day at the factory, and if i remembered correctly the answer was something like "needed only after shutdown" To prevent heat collecting under the cows after shutdown on a hot day i could just open the inspection covers?

Kind Regards,

Jos Okhuijsen
Visit - www.EuropaOwners.org


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terrys(at)cisco.com
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PostPosted: Thu Nov 16, 2006 1:31 pm    Post subject: Oil cooler thermostat Reply with quote

Just a comment on the 'gills'. We spent a lot of time curing our temp
problems on a 912S powered XS, instrumenting and logging in flight
various temperatures under the cowl. Our experiences indicate to us
that the gills significantly hurt cooling in flight and doesn't help
much cooling the engine after shutdown.
In flight, the gills allow cooling air from the front eyeball inlets
to bypass most of the engine, exiting without helping cool anything
particularly hot. Blocking them off completely caused no significant
temperature rise in the top, rear, of the cowl, which remained within a
few degrees of ambient during all phases of flight.
As for cooling the engine after shutdown, only the coolant inspection
panel on top of the cowl seems to help much, the gills are too low to
get much convection action going.

We did end up closing off all but one of the gills, leaving that one
open just in case we missed something, although flight testing with ALL
of them closed off indicated no real reason for having it open.

Just my two cents worth,
Terry Seaver
A135/N135TD
--


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ptag.dev(at)tiscali.co.uk
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PostPosted: Thu Nov 16, 2006 2:04 pm    Post subject: Oil cooler thermostat Reply with quote

Hi! Jos
These are exactly my thoughts.

BTW I'll be in Gallivare? for Christmas and New Year! For a christening


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topglock(at)cox.net
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PostPosted: Thu Nov 16, 2006 8:02 pm    Post subject: Oil cooler thermostat Reply with quote

It's funny how different builds render different results. I was
experiencing high temps, both on the ground and in the air, with the
gills open. I closed them, and temps went up, across the board.
Lowering the water radiator and sealing it to the lower cowl with a
rubber seal dropped temps by 10-20 degrees F. My cowl slits are now
open and temps are normal. I should mention that I did the firewall
mod, suggested by Bob at Flightcrafters, which is sealing the tunnel
(tri-gear) behind the bungies and leaving the factory firewall out,
completely. Lots of air exiting that big hole. The Construction can be
seen at http://www.N55XS.com

Jeff - Baby Blue
240 hours

josok wrote:

Quote:


Could it be, that the combination of open gills, bottom cowl opening and entry holes in front creates a pocket of standing air, or pulls air from around the exhaust over the generator or would it not be better to have a designated, more or less defined single entry and exit point? So doing away with the gills all together.
I've asked Andy the same question on his last day at the factory, and if i remembered correctly the answer was something like "needed only after shutdown" To prevent heat collecting under the cows after shutdown on a hot day i could just open the inspection covers?

Kind Regards,

Jos Okhuijsen
Visit - www.EuropaOwners.org






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