2023 Condition Inspection

A place to discuss the maintenance of flying RV's
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A2022
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2023 Condition Inspection

Post by A2022 »

beginning the condition inspection...

this year, 2023 compression check cold: 78, 78, 76, 72
last year, 2022 compression check cold: 73, 74, 78, 72

I have no idea why the compression numbers go up, but at least number 4 is holding 72. Perhaps using my inlet air dams to keep the CHTs up during the Winter is helping.

first time to take cylinder photos with the new borescope. I noticed some scuffing on number 3-cylinder wall, and need to keep an eye on number 4 exhaust valve. the spark plugs looked good and passed the resistance check.

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I thought my ACOC brace made from 5052 alum tube with the crudely smashed ends had a crack. however, when I removed it and inspected, it was fine, and I reinstalled. 1100+ hours, I'm surprised it lasted this long, probably should be SS mat'l, but I'll see how long it goes.

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Stick linkage (critical area) and cockpit fuel filter....

the linkage looked good, lubed the connections. added a water drain hole at the fuselage lowest position for an A model that I had been thinking about for a while. cockpit 74-micron fuel filter looked fine with very little contamination, pepper flake size. this is the most upstream filter and filters both tanks. the flow direction for this filter is the same as an oil filter, from the outside to the inside. trapped material will be found on the outside. I have been better at sumping the fuel tanks to get the crud out before it gets to the filter. I think it helps. I have never found much in this filter, the first five years I found more contaminants. do I really need it, perhaps not, but I wanted a filter upstream of my cockpit mounted fuel flow meter.

I made a small knee board to ease the pressure on the spar. it worked OK, would be better with a cushion added for comfort.

general wire routing inspection in this area appears fine. do it once, keep it tidy, and never go in there again. I haven't touched it in 10 yrs. there are several extra dead-end wires routed to places if I ever need to add something, so far, they have not been used.

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

2023 condition inspection (10th) is completed. monitoring my one crack on the entire aircraft at the old cooler nut plate. it hasn't changed in the last 400 hours. my shitty little oil cooler stiffening tube seems to be doing its job. today was wheel day. I saved the dirty job for last. the last job was topping off the brake fluid because I always drain some to clear the line. I had some other than Matco brand of brake pad (don't remember the brand, they appeared to be falling apart) and I didn't like them. even though I had some brake pad remaining I swapped them with new Matco pads because it's a quick job. 10 years pumping out the old grease with the new and dropping the wheel bearing back in. out of four bearings races I had one that is beginning to show some pitting. I could not feel the pitting with my finger, but I could see it. I'll probably install new bearings, races and rotors within two years. I probably have a couple thousand landings with these wheels, and they have been good. I am still using the original brake caliper and O-rings, no leaks or issues. for the 10th condition inspection, I would give this aircraft an A+ rating for low maintenance.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

it's purring like a champ. I made it an easy flight today, checking all the systems. one thing I am happy about is that I don't have any blistered fuel tank rivets, none. I did the proseal trick prior to painting that guaranteed they were sealed. takes about an hour. I had a couple weeping rivets prior to painting. it worked. 10 years and no blisters and no fuel tank leaks. if I had blistered fuel tanks rivets it would probably drive me crazy. I don't want a ragged-out RV with fuel tank rivet blisters! people asking why the rivets are popping out of your wing and then you have to explain.

20C OAT today at 4.5K and the engine temps are right on. oil pressure 64 psi, oil temp 176F. time to get my body back in shape and get the heck out of here. for me, the condition inspection service work is the engine and the gear, the other stuff is just inspecting.

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Last edited by A2022 on Wed Jun 07, 2023 1:00 pm, edited 2 times in total.
Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

I think I'll attempt to make a little kit to shoot those fuel tank rivets with proseal from the outside with 100 psi pressure to guarantee no fuel tank blistered rivets. seems to have worked very well for me. it only takes an hour and could save some grief down the road. blistered rivets drive people crazy.

no blistered rivets in 10 years and 1100 hrs and the plane has been all around the country and exposed; Calif, Maine, Florida, Idaho, Texas .... I had a couple weepers prior to paint, that the green Loctite could not solve. I shot All the fuel tank rivets with proseal from the outside.

the kit will be very inexpensive.

when you have a blister-free fuel tank you will be the DOG, but I would rather be the FROG, because frogs get to play in the water more often. :)

Nora En Pure – Gratitude
https://youtu.be/0QeL9cZ7EOs


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

the 100-psi rivet proseal injector. thin the proseal seal with acetone, load the syringe with 5cc, place syringe over rivet and press with 25 lb, wipe off the excess, allow a couple days to dry before adding fuel, done. the flat thin contact surface of the syringe will seal the edges to allow the pressure to build. you will NOT damage the wing tank skin. best to do this when the fuel tank is installed for support of the tank, prior to paint. shoot All fuel tank outer surface rivets.

syringe inner dia. = .567 in, = .25 in^2.
25/.25 = 100 psi



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from the internet.... looks like a nice paint job.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

rockwoodrv9a
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Re: 2023 Condition Inspection

Post by rockwoodrv9a »

Your plane is holding up great. I have done 2 annuals and my 3rd is coming up in October. I will probably have to do the main wheel bearings since the wheels are about 10 years old though 8 of those they were just on the plane while it was being built!

I have a question about why you made the oak board you put on your spar. Was it to make crawling under the panel easier? Also, what borescope do you have? I have this one. It works reasonably well for inspections but I wasnt as impressed with it in the engine. It was not as easy to hold still or shoot back up. https://www.amazon.com/gp/product/B09WM ... UTF8&psc=1

My wife and I are going to fly up to Mackinac Island for a day trip either this week or next and take our bikes. That should be fun.

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Re: 2023 Condition Inspection

Post by A2022 »

rockwoodrv9a wrote:
Sun Jun 04, 2023 8:11 am
Your plane is holding up great. I have done 2 annuals and my 3rd is coming up in October. I will probably have to do the main wheel bearings since the wheels are about 10 years old though 8 of those they were just on the plane while it was being built!

I have a question about why you made the oak board you put on your spar. Was it to make crawling under the panel easier? Also, what borescope do you have? I have this one. It works reasonably well for inspections but I wasnt as impressed with it in the engine. It was not as easy to hold still or shoot back up. https://www.amazon.com/gp/product/B09WM ... UTF8&psc=1

My wife and I are going to fly up to Mackinac Island for a day trip either this week or next and take our bikes. That should be fun.
the board is easier on my knees, but could do with an additional cushion. Vivida 400 borescope, using some Android smartphone app. good luck in Mackinac! I'm planning for the Keweenaw mid June, and may also stop by Empire for a couple days.
Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

some progress.... you really some type of load spreader for this job to save the hand and they will be inexpensive. you can retract the syringe using the load spreader.

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

10 hrs on this hot oil, you have to really look to see it. my last oil change was at 80 hrs and the oil was clean. this time, I am going to 100 hrs because the oil stays clean.

I know some change the oil at 25 hrs. keep doing that if it is dirty. larger pistons will leak more than smaller simply because there is more contact ring length and diameter stiffness effects. besides, it gives you something to do.... :)




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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

thinking about a fixture to be used with a special saw blade (high speed) for an ultra smooth square cut. I also need a fine adjustment feature, so thinking about that. indexing from the lower.


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I'll try one first. shim between the purple and green pieces somehow to control syringe location. I'll probably learn something about this plastic tooling. fun stuff.



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Last edited by A2022 on Mon Jun 12, 2023 2:08 pm, edited 1 time in total.
Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

maybe this will work...


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this was my design goal. I don't know how close I got. I'll measure tomorrow. time for a beer!

Lane 8 - Nuclear Lethargy
https://youtu.be/ANObZHdfX1s

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

measurements.... not too bad for these plastic parts. avg hole is undersized by .005 inch. will be fine.

as for sealing tanks.... if you keep doing the same ole thing, expect the same ole results... blisters and weeping fuel tank rivets. try something new, additionally seal ALL fuel tank rivets prior to painting from the outside-inwards, so you don't have to deal with blisters and weeping rivets. takes about one hour.


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this was the design goal.

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Instructions:

1) Drain the fuel tank

2) Thin Proseal with acetone to allow it to flow

3) Load the syringe with 5cc

4) Place syringe over AN4 counter sunk rivet and apply 25 lb. this will apply 100-psi Proseal to the rivet head.

4A) Alernate: Place syringe over each half AN4 rivet and apply 25 lb, requires two presses

5) Wipe off the excess, it will be minimal

6) Allow a couple days for the Proseal to set before adding fuel

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10 yrs old, 1100 flight hours.... no blistering or weeping fuel tank rivets.

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this concludes my 10th condition inspection efforts. :)

ADZ & Harry Diamond - Medea (Orignial Mix)
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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

I didn't know how much interest this would generate. to answer the biggest question I have had, yes, you can sand the tip off a syringe yourself as I did years ago. here is my photo from the syringe I used. alternatively, you can buy the "weep-no-more" kit I have, it's inexpensive and the end is precision cut with a special blade. the dome shaped palm load spreader will save the hand and allows for good directional control because the syringe push end is trapped in a bore. prior to painting, additionally seal ALL fuel tank rivets from the outside-inwards!


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Weep-No-More, Fuel Tank AN4 CS Rivet Sealer

https://www.rvplasticparts.com/product- ... vet-sealer


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

rivet sealer demo. holes have defects. note: get your arm calibrated for 25 lb. and push straight-on. the first one slipped to the side and the syringe plunger broke but the load spreader protected my hand. hey, I haven't done this in awhile. this is a demo with old permatex #2. it was too easy to pass, I would have filled the fuel tank with sealer. this was a demo only, do NOT use permatex #2 to seal the fuel tank rivets, use Proseal.

prior to painting, additionally seal ALL fuel tanks rivets from the outside-inwards.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

10ml syringes compared. since my test where I broke one of these syringes, could have been bad for my hand if I didn't have the load spreader, I started looking at syringes in detail and found some differences. I believe you want to use the strongest 10ml syringe for the usage. a stronger stem (.008 inch) and thicker wall (.010 inch) was found. so, those that ordered will have to wait until I cut the newly selected syringe. it really is a matter of safety and the differences in syringe strengths are significant.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

take 2 on the ProSeal rivet sealer. a stronger syringe allowed for better dimensional control. std dev dropped by a factor of 3. this syringe is significantly stronger than take 1. required a redesign of the cut fixture and tweak of the palm load spreader. I ripped off 10 and measured them. looks good, ready to go. now you can additionally seal the rivets in place, from the outside-inwards.

Enrico Sangiuliano - Moon Rocks (Original Mix)
https://youtu.be/PzxgOxMq0zo


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: 2023 Condition Inspection

Post by A2022 »

continuing to refine. testing stability at off-angles. .280 diameter holes proved the best, but when I chamfered the end (thinned the material), it became a compliant off-angle beast. a whole new device. so, if you are making these at home smooth the end and it will really shine. I am working on a fixture to get a perfect chamfer angle... or at least as good as I can make it. fun stuff!

did you know an as manufactured CS AN4 rivet head = .210 inch dia.
as squeezed alone, without any other material = .217 inch dia.
as squeezed with two thin sheets = .221 inch dia.

Daft Punk - One More Time (Official Audio)
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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: 2023 Condition Inspection

Post by A2022 »

end chamfer fixture... I believe I understand what I need to do for precise control, but it will require a couple days of design work because I am slow. I'm going to need a beer after this one. ah, the beginnings, the easy part. I need to verify the axial precision of my sanding disc.




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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
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Re: 2023 Condition Inspection

Post by A2022 »

end chamfer fixture... that was easier than I expected, about 4 hrs. everything is printing. axial play in the disc sander is very tight, that's good. maybe it will work. time to spin the syringe.

Lane 8 - Just
https://youtu.be/K3KJBS57nrA


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soft and springy, able to wrap around curved surfaces. 80 grit disc sandpaper used for the chamfer, there may be some benefit for using finer paper, or maybe not. this chamfer was made using nominal model dimensions, no adjustment needed. first part precision!


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
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Re: 2023 Condition Inspection

Post by A2022 »

the maximum force that can be applied = approximately 40 lbs., before the Proseal slips thru the plunger seal. that equals approximately 160 psi syringe pressure. not that you would wish to apply more than 25 lbs. force, but it is a safely relieve valve. to prevent plunger column bending, I will recommend only 2-3 CC added to the syringe. crank up the pressure. these are good.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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