Best of Mail Sack……’Albus D. Onis’

Friends,

I read email in between doing all the other tasks here. Many things require daylight or one’s immediate and full attention. Combing through email requires neither, which is why I often get to it in the middle of the night.

Intermixed with questions, notes and a photo or two are a few gems. when it’s 3:30 am and I have turned myself into a sleepless zombie by absent-mindedly drinking a gallon of coffee after dinner, I will sit a the computer and run through a number of short emails to be productive. In the middle of a long list, I will actually get 10 sentences into an email like the one below before I understand what I am reading:

“Mr. Wynne, I’m so happy and stimulated that I’ve come across your wonderful website. I’ve been struggling with an engine choice for my latest project and I feel the corvair will be the perfect choice after I apply a few modifications.”

I am currently scratch building a 1/6 scale H-4 Hercules from scratch. I designed it to be LSA legal. I’m hoping you can help me with a few questions. Even though I’ve read your website thoroughly and now know as much as you about corvair, the copied copy of your conversion manual that I’m using is faded in spots and the text is illegible. I’m sorry I didn’t buy one from you but I am on a very tight, low fat budget. Anyhow, here are my questions:

Being that I’ll be installing eight engines, how do you propose I synchronize all the props?

Is it possible to share one ignition for all engines to save weight and money?

Will one alternator (i’m planning on using a motor out of an old battery drill i’m not using anymore) feed the ignition, lights, dual 10″ dynon skyviews, dual navcoms, and dual gps’s?

How feasible is to hand-prop the corvair to start it? I can only afford starters for 2 of the engines.

In your opinion, is 1/2″ black pipe strong enough to use for motor mounts?

Would a 1/2 HP sump pump provide adequate pressure for the shared fuel injection system?

Thank you so much in advance for what I am positive will be a most prompt response to my questions.

Finally, I look forward to attending your next college of corvairs edition 24. I stimulatingly dream of meating you, your brother Roy, and your pet falcon, Mark who likes the petunia flowers. If i only come for a few hours during dinner to eat and talk with you at the college of corvairs, do I still have to pay the $79.00?

Fondly, Albus D. Onis”

Albus D. Onis sounds like “Adonis” which is the popular moniker of Corvair 601 builder Ken Pavlou, in reference to his Greek heritage. (I once said ‘Ken you’re as brilliant as Plato!’ to which he responded dead pan “And I have the body of Adonis.”) I was half way into this email before I understood it was a joke. This should tell you both how tired I was and that over the years we have received a number of emails that were nearly this bad that were actually ‘serious’ questions. -ww

Above, I introduce our local host Ken Pavlou at Corvair College #14. In addition to an impressive job at CC#14, Ken has organized many Corvair Cookouts, run the on-line registration for the Colleges, and he set up the format that I use for this blog. On line he likes to be called “The Central Scrutinizer”, a character who is a omnicient narrator in the Zappa opera “Joe’s Garage.”  Outside of the Corvair movement, Ken has a long list of accomplishments: emigrating from Greece at age 8, he has gone on to earn an electrical engineering degree, become a registered nurse and skilled pilot. Happily married and the father of two, he’s also the State Ballroom Dancing Champion of Connecticut (no kidding), and he could earn a living doing stand up comedy. Not bad for a guy who’s barely in his 40s.

Mail Sack, 10-19-12, Piet and Wagabond notes.

Friends,

Here are some of the letters sent in. On the topic of Pietenpols;

Pietenpol builder Harold Bickford writes:

“Thanks for posting this William. The article certainly adds to the information base re: a Piet with Corvair. I’m assuming the Lycoming weighs about what a Continental 65 weighs, i.e. 170lbs. so about 55 of the 95 lbs would be from the Corvair. The performance and CG advantage for the reasons stated are incentive enough to use the Corvair.. I am curious at what gross Bob’s Piet is operating given that the typical gross per Pietenpol is 1080lbs. As an aside enough 1/4″ x 1/2″ was processed over the last two days to make the ribs for our Pietenpol. A band saw, planer and Aerodynamics for Naval Aviators are three useful tools/items that I’m glad are in the shop. – Harold”

Harold, the photo below is our Pietenpol at Brodhead 2000. We flew it up from Florida in 14 hours. We stopped about every 2 hours to take a break and gas up. The empty weight of the plane was 734#. On every one of the loaded take offs the plane was leaving the ground at 1270 to 1280 pounds. At other times we flew the plane as high as 1360 pounds. It was really limited by space, not weight. In air cargo slang it “Cubed out instead of grossing out.”

 

Bobs Piet in the story is 739# empty. He has an 18 gallon fuel system. The 8oo fpm number refered to the plane with full fuel and two 180 pound people in it on a 70F day. The piet is a very strong plane when it is well built. The traditional 1080# gross weight is a number that was based on a Ford engines climb performance limitations. Bob’s previous gross weight was limited to 900 pounds or so on a very hot day for performance reasons, and maybe 1100 pounds on a very cool day with a long runway. These types of limitations on his aircraft are effectively removed by the Corvairs power.

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Builder Sonny Webster writes:

“Saving weight to increase climb is like saving money to increase profits – eventually you run out of places to cut. To increase performance in a sustainable fashion you will eventually need to increase power/revenues.”

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On the temps article with the Wagabond picture;

Builder Jerry Mcferron writes:

“Would you please post the real world cruise, climb, and useful load numbers for the Wagbond?-Jerry”

 

 Jerry, the picture above is just after Gus did the first flight in the plane, he is shaking hands with Dave. You can’t tell these things in pictures, but both Gus and Dave are about 6’3″ and they are both built like NFL defensive linemen. The empty weight of the plane was 804 with a 2700cc Corvair. The plane didn’t have a 5th bearing, but it had the heavier pre-gold oil system. It also had a full panel of vacuum driven gyros. We arbitrarily set the gross weight on the paperwork at 1320# to make it light sport compliant. We did a test flight at 1625 pounds during phase one. I was not worried structurally because we used a PA-22-108 colt airframe as the basis of the plane (this is no long legal under the current FAA guidelines for homebuilts) which has a gross weight of 1650 pounds. The lift struts are off a 160 hp tripacer with a 2,000 pound gross. If you study the gross weights vs the gross climb rates for all the PA-20 and -22 series of pipers, I believe that they set the gross at a number that still gave 500-600 fpm on a standard day. In short it was performance based, not a structural issue. If you are working from the Wag-aero plans and working with wood spars, it would pay to go back and not assume the information to be interchangeable metal spared planes.

The plane is not a speed demon. its fair to say that it will do 100 mph on 5 gallons per hour. It 100 hp climb rate at 1320 pounds is about 700 fpm on a standard day. It is a good all around aircraft, but not an outstanding performer on any single front. We are currently redoing the plane with some detail work intended to clean it up and repower it with a 3000cc Corvair. I am shooting to bring down the empty to 780 pounds or so. We will have more data in a month or two. If you would like to see a video of the plane in flight, look at this link to you-tube, it has 7,000 hits:-ww

http://www.youtube.com/watch?v=B7XhuWmqcPw

 

Measuring Cylinder Head Temps on Corvairs.

Friends

In the last week I have been on the phone with Jeff Cochran, who is flying off the test time on his 2850cc powered Zenith 750. Jeff was concerned about a fairly high Cylinder head temp he was seeing on test flights. I knew that Jeff’s engine was in good shape, he had an overhauled MA3 carb, and he was using our standard cowling. This assured that the temp wasn’t caused by a basic issue.  I verified that he had the timing set correctly and was wisely using 100LL for his test hours. In short, there wasn’t a good reason for seeing the high CHT numbers. Jeff’s probes are the kind that go under the spark plugs. Although these work on countless planes, they can have variations in how accurately they reflect the actual temp of the head. In some cases they are a better reflection of the temp of the spark plug. Although the corvairs plugs are on the top/cool side of the head, CHT measurements taken under the plug will often read higher than those taken from the boss on the bottom of the cylinder head, on the hot side, where GM put the CHT probe in the car. I asked Jeff to re-arrange his CHT probes to leave one under the #1 plug, and move the other to be on the GM factory location on the bottom of #1.  Jeff’s letter back below confirms what I suspected, that his engine is actually flying in the middle of the heat range of the engine and that his CHT probes under the plugs were providing a false high number.

“William, Just a quick update.  Yesterday I flew two hours in the morning without any changes. Came back stripped off the nose bowl and cowling, changed oil, relocated sensors and added the cowl lip extensions. On the sensors, I left one under spark plug #1 and moved the one from spark plug #2 to the location under cylinder #1. That way we get a direct comparison. After all of the changes I flew another hour. On climb out the spark plug CHT got to 458 deg. F and stayed over 450 for the rest of the climb to 3800 ft. The sensor under the cylinder reached a max of 349 deg. F for about one minute.at the end of the climb.  During cruise the temps were around 420-425 vs. 325-330. The average difference between the two was normally over 90 deg. F. The largest difference was on climb out when the lower sensor heated up slower and I saw 119 deg. F difference. I feel much better about the engine now.-Jeff “

Pink Ticket

Above, Jeff stands on the left with his 750 on the day of airworthyness.

   

Above, Jeff sent this photo of the CHT probe moved to the bottom of the head. The hole he put it in is the stock GM location. On a 95 or 110 head this hole is threaded 3/8-16. Get a bolt 5/8″ long with this thread and an area washer, and you can clamp an under plug style sending unit right to the flat boss. If you are starting out from this position, you can use a 10mm spark plug sending unit because they are .400″ in diameter and a 3/8″ bolt is .375″, and it will be a little neater than using a 14mm sending unit. This location is where GM measured the 575F factory CHT limit from. We don’t recommend using that limit on flight engines, but they can take it as long as the engine isn’t allowed to detonate. Very high temps that are caused by detonation will obviously result in engine damage, but a Corvair that isn’t detonating has a very high cooling margin. Jeff showing numbers like 350F may sound very hot to a Jabaru operator, but on a Corvair he is 225F below the proven red line. Jeffs engine is running right in the middle of the thermally efficient zone and also is running a a temp the reduces the amount of lead build up in the engine compared to an engine running cooler. Keep in mind that a 750 is a large slow climbing aircraft and this effectively shows that the Corvair cools very well with a very wide margin in this heat challenged installation. 

Above is Rich Whittington’s fabulous looking 601 HDS at Corvair College #21. Rich actually was one of the first builders to verify the under plug vs GM bottom location temp differential in independent testing last year. Rich’s results were much like Jeff’s. 601’s and 750s have very similar installations, sharing the same cowling and baffling. The 750 is bigger and climbs slower, but still cools itself well using the same parts we now have flying on more than 60 601’s.  Rich’s aircraft has a 3,000cc engine with a Roy bearing

Flycorvair.com: An underutilized resource

Below are some photos and information I pulled from our main website Flycorvair.com. I went to that page, and typed in “spark plug washer” in the search box at the bottom of the front page and it spit out a number of links like the 2008 entry below. The page you are reading right now is Flycorvair.net, which I think of as our daily news paper of the Corvair movement. we have now had it for 10 months, and it had more than 100,000 words on it in 120 articles. But this is puny compared to Flycorvair.com, our main page that we have had for 12 years, which actually has more than 25 times as much information. Granted, it is not perfectly accessible, but many people fail to even try the search engine on it for basic answers. People today are often impulse driven to want an instant answer, rather than reading a little, learning and developing a real understanding of the answer to the question they asked. Flycorvair.com is a main library and the store for our business. It is a resource more builders should use. (note: below is a source info for copper plug washers in 14mm.)

From 2008, “Above is a photo to put a few things in perspective. The eight sparkplugs in the photo are replacements we just got for the Taylorcraft. On Gus’ advice I picked up iridium plugs for the bottom of the C-85 and standard plugs for the top. Make sure you’re sitting down: These eight plugs cost $375. That’s pricey. However, consider this perspective: Small Continentals on classic American airframes are some of the most reliable and trustworthy aircraft ever built. Even with 70 years of age and stingey or inept maintenance, these planes soldier on with an enviable record of reliability. Since this reliability is the foremost attribute of the plane, I am always willing to spend money in order to maintain that attribute.

A C-85 has a 6.3:1 compression ratio. This low ratio and its magneto ignition system make it prone to fouling plugs when run on 100 low lead. By comparison, a 9:1 compression ratio Corvair with one of our 35,000 volt ignition systems is immune to plug fouling. Also in the photo is Champion sparkplug lube, Part No. 2612. This is an absolute must for plugs going into Corvair heads. Plenty of people try silver anti-seize, but that’s a mistake because it gets on the plug’s insulator. You can also get 14mm copper washers for your Corvair plugs from Chief Aircraft, Part No. CH-M673, at about 40 cents a piece. If you’d like to experiment with iridium plugs in your Corvair, Denso makes a Part No. IWF16-5359. Please note that we tried platinum plugs with 100 ll fuel and it’s a poor combination.”

Above is a shot from 2006. Evidently I didn’t always have long gray hair. Merrill films Whobiscat and I in front of Rick Lindstrom’s Quick Build Zenair 601XL in our hangar. This aircraft had a glass cockpit. It had purpose made CHT probes that were expensive and threaded directly into the 3/8-16 holes in the bottom of the heads. These were made to feed information to an engine monitor made by the highly respected IK Technologies. These reflected the same temps as 10mm ring style senders clamped down with washers. The photo is a good indication of how long we have been gathering data and techniques on these specific subjects.

Above, a photo of the Wagabond built by the hangar gang at the old Edgewater hangar. This photo is from Corvair College #10. This is a very large plane that climbs slow. To this day, I think that no Corvair powered plane has left the ground at a higher gross weight (1625 pounds) We finished this aircraft eight years ago. It gave us a lot of test data that proved useful on aircraft like Jeff’s 750. Good data and useful answers are not developed in a day, and companies that are here today, gone tomorrow place very little value on gathering information, and even less on teaching builders things for the long run.

Above, is the Wagabond’s front end in a Corvair College #9 photo. Note that it basically uses the same nose bowl and cowl as we use on Zenith 750s (the carb air inlet is different on a zenith). This is how I knew that Jeff’s plane would cool itself well, and why I suspected an instrumentation error. We have long known that this type of cowl works well, even on big, slow climbing planes. We don’t use customers as guinea pigs, we promote things after they are tested.

 

Above, another Flycorvair.com photo from Corvair College #9. The aircraft is the turbo skycoupe, a major test bed of ours between 2001-06. If you look on the cowl ahead of the pilot, the white 3″ outlet pipe from the turbo is visible. Note that this aircraft also uses the same nose bowl we sell. The skycoupe isn’t big, but it wasn’t real fast, and the turbo could generate a lot of heat to go along with the power. (During a static run up this plane could drag the tires on dry concrete with the brakes locked. We tested the combination to 60″ of manifold pressure.) This aircraft sustained 500F CHT’s measured in the GM location. It also ran EGT’s over 1600F. Naturally aspirated Corvairs don’t generate this kind of heat, but it is good to know our favorite engine can take it. Today this airframe is owned by Craig Anderson who is restoring it and installing a 2850 he built up after Corvair College #22. Look for the Skycoupe to be at Oshkosh 2013.

 

Above, Dan Wesemans “wicked cleanex” in 2007. Although powered by a 3100cc engine and flown very hard, this aircraft never had issues with running hot. In a previous post on oil systems, I have a good shot to the engine installation. Fast small aircraft like the Cleanex do not challenge the cooling. Even if they climb only 25-30 mph faster, you have to keep in mind that dynamic pressure increases with the square of airspeed, and the energy of the incoming air is a lot higher, even if the airframe is only a bit faster. In cruise, these planes run very cool. Chris Smith, who built and Flew the “son of cleanex”, often had cruise CHT’s in the low 200’sF. Likewise, fast aircraft like these do well with stock 12 plate oil coolers. The larger and slower the plane, the bigger the oil cooler it needs.

Above, Grace and Mark Langford in front of our house in 2011, when he reached the 1,000 hour point on his plane. Very fast aircraft like Mark’s have less CHT difference between the top and bottom of the head than a bigger plane like a 750. Mark documented many time that his aircraft ran very cool in high cruise flight. Corvair powered aircraft with this wide a speed envelope could be a good candidate for a cowl flap arrangement. Zenith 601 builder-pilot Andy Elliot is experimenting with a cowl flap on his 3100cc zenith, it shows results, but it wold be most effective on very fast aircraft to cut down on the amount of cooling air going through the engine. Running too cool is an issue that few auto conversion engine ever have to face. The very good cooling of the corvair, in combination with the fact we run the engine far below its automotive output and it’s 575F redline make the Corvair a reliably cool engine in experimental aircraft. A statement that we can back up with a long track record of testing verified by our builders. -ww

Pietenpol Power: 100 hp Corvair vs 65 hp Lycoming

Friends,

Bob Lester flew his Pietenpol, newly converted to Corvair power, over to our airstrip this morning. I wanted to get a look at it, and run a weight and balance with the same electronic scales that I used to do the calculations last year when the plane still had its original Lycoming 65 hp engine installed. The information is interesting because it is data that dispels misconceptions that many people have about aircraft performance.

Above, Bob stands beside Grace in our front lawn in December of 2009, when the plane was still powered by the 65 hp Lycoming. The 2009 photo caption said “On an overcast, blustery Sunday, we were surprised with a visit from Bob Lester. He lives on the other side of Northern Florida, and bundled up and flew over. His Piet was built in the 1970s, and sports a Lycoming 65 hp power plant. Bob found the aircraft in Arizona last year and flew it back on a 25-hour adventure. From my first days in aviation, I really wanted to live on a grass strip. Fifteen years of hard work later, we made it. Having old friends taxi into the front yard is one of those moments that makes working past midnight on two thousand nights and saving our pennies worthwhile”

Although Bob really liked his Piet, it had marginal performance on the original engine. In spite of being we built and fairly light, the plane barely had a 300 fpm climb rate solo on an average day. With two people on a very hot Florida day,  Bob said that he had found the plane to just barely have a positive rate of climb. If you live in the rural midwest, you might not think of this as critical, but Florida has the combination of hot and humid weather, short grass strips, and some types of terrain and restricted airspace that makes a plane much more useful if it can climb to 2,000′ agl in two and a half minutes rather than 10 to 12 minutes. The biggest issue with any plane with this poor climb, especially a four-cylinder one, is that is you have any problem, like having one mag cut out, the aircraft will not climb, and you are going to have a forced landing.

  Additionally, Bobs Lycoming, like it’s 65 Continental brethren, was a hand prop engine, and it was problematic to start when hot. I looked at the details of Bob’s old engine, and there was nothing wrong with it, the impulse on the mag worked, and the carb was set correctly. It just that heat soaked mags on a 6:1 compression engine with a wood prop isn’t always an easy starter. This issue was an additional factor in Bob’s choice to go with a Corvair. Bob had been flying with a Corvair since 2001 when he removed the Subaru from his KR-2 and replaced it with a 2700cc Corvair, so he is not new to the movement. Bob had built a 2700/Dan bearing engine and run it at CC#17 and briefly flown this on his KR, and now had it available for transplant. A few months ago Vern and I made Bob a custom motor mount and an intake for a Stromberg carb, and he went to work on the engine swap.

The results: Lycoming 65 hp; cruise 65 mph, top speed 72, gross climb (at 59F) 250 fpm. With Corvair: cruise 75, top speed 95 full gross climb (at 75F) 800 fpm. Solo climb rate 1,100 fpm. Bob installed a battery and electrical system with his Corvair and changed his fuselage fuel tank to aluminum from fiberglass, and made a very quiet muffler system. The empty weight went from 644 to 739 pounds. Yes, the above measured performance increases are with an aircraft that weighs nearly 100 pounds more than before. 35 extra hp is worth far more than 100 pounds less weight. I can not count the amount of times in the last 25 years I have heard someone pontificate in a hangar flying session just the reverse of this reality. Yes, building things light is important, but the empty weight of the plane is not the single factor in climb rate. If you have an ‘expert’ at your local airport that debates this, just know that he has never done a test like we just did with Bob’s aircraft.

First question is how if the plane got 35 hp added to the original 65, an increase of 54%, does the plane now climb at several times the original rate? Planes climb on excess power, not total power. If the climb speed is 60 mph, first consider how much power it takes to fly the plane straight and level at this speed. In Bob’s case, it might be 50 hp. From that point, the Lycoming only had 15 hp available to climb. At the same 60 mph, his Corvair has at least 50 more horses in reserve for climb, a 330% increase in climb power. Just saying this, I know will generate disagreements from net, but the people who don’t understand it don’t own a well-worn copy of Aerodynamics for Naval Aviators, far less a B.S. in Aerodynamics and Performance. If your new and having a hard time picturing it, think of any plane at top speed in level flight.  What is the possible rate of climb? always zero. The plane is using 100% of its power to go forward, it has none for climb. If the pilot pulls back on the stick, yes, plane climbs, but first it instantaneously slows down. A planes best climb speed is near the L/D speed, (the best glide) because this is the point in the envelope where the plane requires the least power to fly straight and level, thus having the most power in reserve for climb.

Also very important in a Pietenpol is the CG location. The range of the design is 15-20″ from the leading edge. Ryan Mueller and I have done a lot of work accurately documenting the CG of examples of the design. Many builders over 160 pounds with light engines are actually flying behind the aft CG limit, which is a great idea if you feel you have already accomplished every thing you wanted to do in this life. In my book if, you want to knowingly fly out the aft cg limit of a homebuilt, it’s your choice, I don’t base my happiness on the actions of others. If someone wants to tell other people this is a good thing to do, then they will find me disagreeable. If a guy wants to go a step further and fly passengers who know nothing about CG, like little kids, they will find me to be a vocal opponent of theirs, no matter who they are. When it comes to speaking up for the safety of unwitting passengers, I am not intimidated by any combination of the offending pilots wealth, experience, popularity or physical size far less peer pressure or being thought of as a mean spirited sob.

Bob weighs 210 fully dressed up for open cockpit flying. with his Lycoming, his plane was flying near the back of the CG range at 19.1″. With the Corvair we moved it forward to 15.9″ This is a dramatic shift, and it would now take a pilot over 320 pounds to move his CG to the aft limit. This is a much better position to be in. Piet builders interested in comprehensive CG info can get the 5 article series in back issues of the Brodhead Pietenpol association newsletter http://www.pietenpols.org/.

Bob will have his plane on hand at CC#24. He is retired now, and he plans on doing lots of flying in his bird, traveling the country as barnstormers did. He now has a good simple smooth and powerful engine to serve him. If you have similar ideas, sign up for the event and come get to know people who share the same dream.-ww

 

Mail Sack, 10-16-12, Unicorns vs Ponies, CC#24

Friends,

A few comments on the subject of Unicorns vs Ponies:

Old School EAA member Dan Branstrom writes:

“Great writing! Over the years, unfortunately, in the airframe aspect of unicorns, there have been many designs debuting at Oshkosh that represent the wings of unicorns. The most spectacular being the BD-5, which garnered thousands of orders, and shipped hundreds of kits, minus an engine before going belly up. It is a sexy plane, and it was supposed to go fast on little hp. Read the sad story under “Bede BD-5″ in Wikipedia. Yes, there’s a number flying,but they’re modified substantially from the original, and way too many pilots died along the way. You can not only lose money and time on unicorns, but your life.-Dan”

Corvair/Merlin on floats, builder and flyer Jeff Moores of Canada writes:

“Very smartly done, William. That was humourous, insightful, and sadly true. Many would-be builders waste too much money on unicorns. I am very pleased with my WW Corvair Pony!!-Jeff.”

Builder Harold Bickford writes:

“Hi William,
It looks to me like the internet guy aka TB is thinking about automotive or race applications.and high rpm levels. Nonetheless his commentary is only speculation. If he would take the time to read the SAE papers from Chevrolet specific to the Corvair he might better understand why and how Ed Cole and company designed the engine and car the way they did. Or he could read what the tuners of the day did and why. In either case they did the work (engineering and/or tuning) and it was for automotive and not aero applications. And they did “find” the 15-20 HP with far simpler changes than this fellow is imagining but again it is an automotive application.

As we know, Bernard Pietenpol realized the engine had potential for aircraft use and pursued that path. You and your cohorts have gone from there and developed a good 100 HP engine based on the Corvair. When folks ask why I’ve chosen to use a Corvair for the Piet the first question to them is this: what do they know about the Corvair? Almost immediately they want to change the subject. It may not be fun for them but does provide a great opportunity to have a factual rather than speculative understanding of how and why the Corvair is a good choice for a variety of aircraft. -Harold”

Waiex/120 hp Corvair builder Greg Crouchley writes:

“Excellent post! Seems that 1 unicorn converts nicely into 100-120 ponies. Looking forward to 24- Greg”

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750 builder Blaine Schwartz commented on Corvair College #24,

“William, CC#24 looks like it will be a fantastic event! Due to work and distance it took a while, but I finally made it to CC#22 in Austin and had the best time of my life! I underestimated the great group of motorheads and the help you provided me while assembling my 2850cc engine. The friendship and learning that the CC provides is simply not available anywhere else. I hope to be in the air soon and plan to fly in to my next CC!- Blaine”

 

Corvair College #24, twenty four days away…..

Friends,

We are now approaching Corvair College #24. I spent all day working in the shop on college prep stuff and building a stock pile of parts. Vern and Terry have put in a large effort with me in the last 10 days, including overhauling the run stand and  making a lot of detail changes to it that will allow much faster engine changes.

In the morning, Bob Lester is flying over in his Pietenpol. This aircraft used to have a 145 cid 65 hp Lycoming on it, but Bob installed his Corvair in its place. By car, it take 2.5 hours to drive to Bob’s airport, but the Piet can now do it in 65 minutes. Bob got a 20 hour test period and flew it off without issue in 10 days. He is headed over here so we can do a weight and balance on the same electronic scales that I measured 20 other Piets on in the last 2 years. Bob reports that the planes climb rate is nearly four times higher with the Corvair. (Yes having 2 times the power can do this because planes climb on excess power, not total power. ) Bob is already signed up to bring his plane to CC#24. P.F. Beck our local host in Barnwell has his own Corvair powered Piet, so we will have at least a pair of them. I spoke with a 750 pilot who is working to fly in and we are also expecting a Cleanex and several 601’s. It promises to be a very good turn out.

The event will be a large, full-scale College held at the same location of the highly successful Colleges #19 and #21. Corvair/Pietenpol builder/flyer and Cherry Grove Trophy winner P.F. Beck, and his great crew, again are the location hosts.  The prep work for the College has been ongoing for 10 months, and it builds on the outstanding work that P.F. and crew did in earlier years. We are going to close the regular registration before the event, don’t wait until it is too late to sign up.

The link to the registration is: https://corvaircollege.wufoo.com/forms/corvair-college-24-registration/

If this is going to be your first College, I highly recommend that you read about all the previous ones at this link to our main Web page: http://www.flycorvair.com/cc23.html

Unicorns vs Ponies.

Friends,

Today we look at the timeless question, Would you rather have a Pony or a Unicorn? Seems simple enough. Only a mentally injured person would rather have a pony. First let’s list all the Unicorn advantages:

1) They are magical. 2) Many of them can fly. 3) They are incredibly gentle, and a favorite of little kids everywhere. 4) They have no care and feeding requirements, apparently live forever, and they have never caused a moment’s distress to any living thing.  They are so nice I have it on good authority that when they fart it smells like roses and small cloud of butterflies are gently released.

3d render of an unicorn Stock Photo - 10442790

Above the Classic unicorn. Almost always found near waterfalls or ends of rainbows.

white and black pony with dirty hair standing in the snow Stock Photo - 8579493
Above, typical pony. White one is deciding to kick or bite photographer; probable answer: both. You do not need a scratch and sniff application to understand that this animal does not smell like roses.

 Disadvantages of Ponies: 1) They are mean. 2) They require care, including tasks like de-worming. 3) They smell, and they like to defecate at random. 4) All ponies understand that for the last 10,000 years man has enslaved their kind, made them work in coal mines, horrific children’s parties and participate in one-way arctic explorations. Man has even dined on them. Given a moments in attention on your part, any pony will strike a blow for his species. Look it up, ponies and burros team up to kill 6,000 humans on this planet each year, mostly in third world countries, but they also know where you live. You may have read and loved Misty of Chincoteague as a kid, but Ponies still view you as a legitimate combatant. Ponies are ‘inhuman’ like that.

basically, Unicorns are better than ponies in almost every single way describable….With one somewhat important exception. There is no such thing as a Unicorn.

Except in Experimental Aviation of course, where unicorns are alive and well, written about all the time, they have websites devoted to them, and magazine editors write glowing testimonials about them all the time. If you would like to see one in person, go to any airshow, dress well, fatten your wallet with folded paper and hold your check book and a pen in your hands. Walk up and down the rows of vendors and you will meet unicorn breeders by the score.

Now, just like puppies, you can’t take a new unicorn home right away. You can pick him out, select some options and leave a deposit, but most unicorn breeders will explain to you that your new unicorn is “just coming out of development,” and will ship shortly.

Some breeders are “expanding” so rapidly, that they will offer you a ground floor position at “Aero-corns LLC,” which will entitle you to a pick of the new litter, which is just 60-90 days from delivery, if you are just willing to become an investor in their new stable.

I have been in the business of ponies for more than 20 years. We teach how to breed your own and how feed it and care for it. I teach people how to make a pony work with you if you raise it from the beginning, feed it well and always treat him with respect. Countless times in the last two decades I have had people new to aviation ask “Why would I want a fat 225 pound pony when I can have a 178 pound Unicorn?” and “Why would I bring up my own Pony if he is only going to live 1500 hours? I just read a brochure that says every Unicorn lives between 3000 hours and forever.” and lets not forget “Why is your Pony so thirsty? They have Unicorns that work just as hard and only drink 2.2 gallons/hr.” It goes on and on, and the people who ask these things regard me as mentally ill for sticking with my Pony. I try my best to be polite because I know that the sure sign of mental illness is not being able to distinguish between reality and make believe.

My introduction to “Unicorns are better than ponies” began here. The above photo is from 1995. I am on the left, leading the All Embry-Riddle team that built the First V-8 lancair. In the background, N420HP. It went on to be on the cover of the July 1997 sport aviation. In the Oshkosh air race, the plane logged a blistering 385 mph measured leg. This was one bad pony. The booth next to ours was a Unicorn factory named “Eagle LLC”. They had little more than a firewall mock-up of a V-8, nothing even ground running. Their signs said their target was a calculated 360 mph, something we had already eclipsed the day before. Through the magic of Unicorns and 24 hour Kinko’s, all their signs were revised the next day to say their calculations now were 400 mph. All week-long people asked us why our aircraft was “slower than Eagles.” Our engine guru Al Jonic pointed out that we could never make a real plane go as fast as an imaginary one. Few people listened, Unicorns are more interesting than any pony, Even a pony who’s name is Four hundred twenty horse power. (N-420HP).

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Back in February I wrote a story here called “lifestyles of troglodytes” A sub plot in the story was some jack ass known on the internet only as “Stealthpilot” wrote a completely wrong set of information about the Clark Y airfoil in 2009.  If you look around the internet, there are literally a dozen sites that reference “stealthpilots” information as if it were written by Wilbur Wright as a submission to Jane’s all the worlds aircraft. This is important to remember, that just because you come across several references to a particular unicorn, doesn’t mean that it is a real animal.

 One more warning for the squeamish; When looking for a picture, avoid Googling the phrase “dirty pony.” It will be one more reminder that the internet isn’t really the greatest of human acheivements.-ww

Mail Sack, 10-11-12…..Cleanex notes

Friends,

On the topic of Intakes and the Internet,

West Coast Pietenpol builder Pete Kozachik writes:

Thanks for the informative (and very entertaining!) piece on vapor-expertise vs. real-world expertise. That rear alternator mount looks great! Have been waiting to see it since you described it some time ago. How does it test out?

Pete, Dan and I are still working out manufacturing details, and then are going to stick it on a test bed aircraft. We want to affirm that the unit spins fast enough and runs cool enough in an actual engine compartment. We will have all the parts at Corvair College #24.-ww

500 hour Zenith Corvair builder/pilot Andy Elliot writes:

“For anyone who would like to learn more about the truly amazing development of piston engine technology during WWII, I wholeheartedly recommend the book “Allied Aircraft Piston Engines of World War II”, by Graham White. It is published by the Society of Automotive Engineers (SAE) and is available on their web site (http://books.sae.org/book-r-154) for only $60.
The development of the V-1710 is covered in detail, from the first 650 HP version built for the Navy in 1931, through the development of the “ram’s horn” intake manifold in 1935 which resulted in the 1000 HP -C8 version in 1937, through to the G model which made 2200 HP (with ADI) at 3200 RPM, but never saw large production as the war ended. (They are used at Reno, though.)
As is well described and documented, the V-1710 was ahead of the Merlin throughout most of its life, but suffered for its single-stage engine-driven supercharger when Rolls-Royce added the 2-stage, 2-speed, intercooled/aftercooled supercharger with the -60 series Merlins.
Allison introduced the -199 version of the V-1710 for the XP-51J, the fastest of all the Mustangs. It used a 2-stage supercharger with a liquid-cooled aftercooler and was the first to meter fuel directly into the supercharger without a carburetor. It produced 1700 HP, at 3200 RPM ** at 21000 ft! **
Another very good book, specifically about the V-1710 is “Vees For Victory!: The Story of the Allison V-1710 Aircraft Engine 1929-1948″, by Dan Whitney, who provided engineering support for Reno air racers for many years. Available on Amazon for $50. Interestingly enough, if you check out the presentation at http://www.enginehistory.org/Reno/EngineeringUnlimiteds120304.pdf, you’ll find about 1/2-way through, a picture of Graham White at Reno in 2002, working with Pete Law, who is more or less the “godfather” of racing engines at Reno! -Andy “

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On Cleanexes, builder Jackson Ordean writes:

I’m amazed there aren’t more Sonex powered by Corvair? Beats Aerovee by any measure, not to mention Jab. Anyway, just keep up the awesome work – hope you guys are blessed doing it.

Jackson, Different engines for different people. We try to just present the appeal of the Corvair without getting in to debates about merits. Over the years I have found that guys who just want a by-it-in-a-box  imported engine have very little interest in Corvairs, and people who really want to know every nut and bolt on their airframe and engine will find little satisfaction in engines from companies that are focused on selling a consumer good rather than an educational mission. This is the most important division in engine choices. A guy who really wants to be self-reliant and his own mechanic, but buys a Rotax 912 because its lighter than a Corvair, isn’t likely to be happy in the long run. Neither is a guy whose sole interest in Corvairs is because they are comparatively inexpensive. This is why I spend a lot of time speaking about philosophy and motivation, these are important things to understand before people start shelling out money.

At Oshkosh last year, a nice enough guy, new to homebuilding showed me a spread sheet he had made with every possible 100-120 hp engine on the market. A lot of the data was brochure stuff like liquid cooled engines weighed without water and fuel burns a Cox .049 couldn’t match. This guy even invented new concepts like engine weight divided by dollar cost, not a particularly useful value. I tried to get him to switch gears and think differently by pointing out that his marriage works because he and his wife are a good philosophical match, not because her height x weight divided by her gross income is in some target range on values. I think he understood the point, but I suspect he went home and graphed out the last equation.

On the subject of Cleanexes, There are a lot of photos of them on Dan’s site Flycleanex.com. Hard to believe, but Dans plane has been flying for seven years. Time waits for no one. In the first years, Dans plane was followed quickly by Chris Smiths “son of Cleanex.” At the time there was debate about what the ‘right’ engine was, or how well the Corvair worked in the sonex airframe, mostly driven by people who spent a lot of time on the net and had never seen a Corvair or Dans plane. 

In the foreground Dan’s Cleanex, behind, Chris in the “son of Cleanex.”

In 2009 Dan and Chris flew up to the Crossville fly in for Sonexes. Chris later told me that he and Dan, who fly together a lot, did a full power, formation flyby at 5 feet, 180mph, 3,500 rpm and 12 cylinders, followed by a sharp pull up and a clean break. Chris said after the came back around and landed it was like Lindbergh landing in Paris, they were mobbed and questioned by people who had only heard from internet experts that the Corvair was a heavy, oily, old American engine that made no power. After one look at reality, opinions change. Today there are about 14 Cleanexes flying. many of these were built by people who were present at the Crossville moment, and they cite the sound and the power as the decision maker. All of them report that the performance had been astounding, partially because the internet experts, people who had never seen the Combination fly, had them expecting much less. One of these successful Cleanex builders whose mind was made at Crossville is already regestered to fly his creation into Corvair College #24-ww

Gold Oil Filter Housing, Standard and Reverse

Friends,

Here is a big chunk of information on Gold oil systems. I have been making these parts for 6 years now, and they are on nearly all of the new flying Corvair powered planes and they have been retrofitted to a large number of engines built before 2006. The information here is a mixture of new comments, but a lot of it is directly off our Flycorvair.com website, which is best understood as our library of Corvair information, while this site, Flycorvair.net, is our newspaper of the Corvair movement. There is a tremendous amount of information on .com, all best accessible through the search box at the bottom of its main page. At Oshkosh this year I actually had a guy complain that there was “too much information” on Flycorvair.com. Yes there are about 1,200 pages of it, and it isn’t perfectly organized, but I think most builders prefer that I publish extensive information rather than less about Corvair flight engines.

The Filter housing, and the optional Sandwich adaptor and HD oil cooler make up the ‘top oil group.’  It serves many more functions than relocating the oil filter. This system is specifically designed to have an oil temperature monitoring port at the place in the engine where oil temperature is highest. Additionally, the oil pressure ports are positioned to measure oil pressure at the lowest pressure in the engine. Having these measurements taken at these locations offers flyers the most accurate information.

Above, several views of the Gold oil filter housing. It can also be clearly seen on the 3,000 cc Corvair photo on the previous post on Intakes.

There are many more pages of information on these housings on our products page on Flycorvair.com at this link:

http://www.flycorvair.com/goldoilsystem.html

For builders who are not yet well versed in the layout of flight engine oil systems, I wrote a long piece on the best 6 possible combinations. I wrote this in 2007, and it is at the link below. It gives a good over view with photos.  Looking at the dates shows how long we have been working with Corvairs. I made the prototype Gold housing in 2005, yet in the big picture, this is one of our later developments. These systems are on at least 250 running engines. Old and proven is more important than new and exciting if you are actually planning on flying.

http://www.flycorvair.com/hangar1007.html

 Our main mission is teaching people to build engines. An integral part of our system is that I must have some way to monitor from a remote location how well the builder did. Our system for this is elegantly simple. When a builder completes his engine and installs a known propeller such as a Warp Drive, he can perform a full power run-up and tell me what the full static rpm of the engine is and what the oil temperature and pressure is. Because of the standardized propeller, I will know if his engine is correctly assembled and making its full rated power by the RPM that it turns. Additionally, I will be able to tell a lot about the internal health of his engine by knowing the temperature and pressure of the oil. This is only possible if he is taking these temperature and pressure measurements at a standard, known location. This is the true nature of the gold oil filter housing, FlyCorvair.com/goldoilsystem.html, and why I consider it an indispensable part of any engine conversion.

Above, a 3100 cc Corvair I built which we installed on a 750 airframe at a West Coast College in 2009. This engine has a 45 amp alternator sitting where the oil cooler normally goes. We built and flight tested this Charging system on a 601XL in early 2009. It means that the oil cooler must be relocated to the firewall and fed with a scat hose. This has been well proven, but it isn’t where we headed today. This shot clearly shows the Housing and sandwich adaptor in place. There are videos of us getting this aircraft running that day on You Tube.

 In the past, many people would call up and offer data like “my oil temperature is 230°”. If this temperature is after the cooler, it’s a bit too high. If this temperature is before the cooler, it’s just fine. In plumbing unique oil systems, many early builders were unsure whether their temperature measurement was before or after the cooler. A lot of erroneous or inapplicable data was tossed around by people running engines and reporting the results on the Internet. The gold oil filter housing with its integrated instrumentation ports has simultaneously eliminated poor data and allowed us to confirm that builders have done an excellent job with their own engine.

 

 Above, the layout that I much prefer: The Cooler mounted on the engine with the alternator up front. This has been shown to work in the hottest environments, and has a clean simple installation, even with a HD oil cooler. 22 amp alternators work on every plane we have tested, modern electronics use no power by comparison to traditional stuff. Braided hoses work great, but we are investigating having CNC robotically bent stainless hard lines made by an aerospace manufacturer. Since the engine and cooler are fixed to each other, hard lines are an option. Dan and I are currently testing the rear alternator seen on the Panther prototype 3,000 cc engine. It will be able to be integrated into the system seen above. We will have it on display at Corvair College #24. The above photo is also a good look at the inside of an Electronic/points distributor. The baffling kits on both of the engines shown are from Jim and Rhonda Weseman at JSWeseman.com.

Additionally, the housing takes a modern, light weight, high quality, replaceable filter that is readily available. The most frequently misunderstood part of the assembly is the unwarranted worry which some builders have that the system will spill oil when it is being changed. The filter we use is a modern design that contains an internal check valve that prevents it from spilling oil as it is spun off. Holding a small rag underneath it while unscrewing it is all that it takes to prevent a mess.

 To the tiny minority of potential builders who still have trouble imagining touching an oily rag, I suggest that they await the development of electric aircraft that will not require them to have a single masculine moment in aviation.

We offer two different versions of the gold oil filter housing. The standard version points the filter out over the harmonic balancer. The reverse housing places the oil filter over the top cover of the engine. Either of these systems works with our heavy-duty oil cooling system. Almost all aircraft take the standard housing.

Above, Dan Wesemans ‘Wicked Cleanex’ with the first Reverse Gold oil Filter housing mounted in place. The housing did a lot to clean up his engine compartment which previously had a remote filer mounted on the firewall fed by braided lines. Because the Cleanex uses a stock 12 plate cooler, the only external oil line on Dans plane is the one feeding the 5th bearing.

The reverse housing was specifically developed for Sonex airframes to clear their fuel filler neck. It has other applications where space is at a premium, such as a Kitfox Model IV, and on turbocharged Corvair aircraft which use space behind the engine for the additional plumbing. Our gold filter housing comes with all of its mounting hardware, and directions for its installation.-ww

Intakes and Internet myths

Friends,

Everyone who reads my notes regularly knows that I bitch and complain about how well the internet serves as a venue for anonymous “experts” to pretend they are smarter than people who are actually out building and flying. Maybe it’s been a few days since I shared another example? Heres one that was served to me on a silver platter. It also involves a common myth about engines that is a favorite topic of arm-chair engineers and experts.

Above is a picture of the 3,000cc Corvair we assembled for the Panther prototype just before Oshkosh. The Corvair all-stars shared a display at Oshkosh again this year, and the Panther with this engine on it was the centerpiece of the booth.  This angle shows how GM engineered the intake logs with an offset in them, this is specifically related to the flow vs firing order. These heads have astoundingly good mixture distribution for a carborated  engine. This has been confirmed by a number of flyers with 6 cht’s and 6 egt’s. On his own website, a very nice guy named  Steve took the time to say that he went to Oshkosh, met Dan and myself, that he really liked the Panther, and he put up a number of good photos that he took himself of the airframe and engine.

Enter the Internet expert…..Identified only as”Toolbuilder,”  from California. Although this guy was not at Oshkosh and probably has never seen a Corvair in person, he posted the following comment on Steve’s website. 

” I’m not a fan of the intake and exhaust on that Corvair. I think there is a lot of power that was left on the table when they went with the log style manifolds. To me, that’s the last resort, and you only go that way when the proper individual runner manifolds won’t fit. I’d bet there is 15 – 20 HP hiding in that engine with proper manifolds.”

Where do you start with an anonymous ‘expert’ like “Toolbuilder”? Do you think his friends told him that the email name he selected is also a specific low ranking job on a pornographic movie set? Maybe they knew this when they suggested it to him? Should we talk about how many dyno runs of Corvair engines he has made to offer a HP improvement so specific? Maybe we should just confine it to a small historical comment and a photo of a Corvair on our dyno….

Allison V-1710

Above, an Allison V-1710 cid V-12 engine from WWII. This engine is a General Motors product, just like your Corvair, Not in today’s Corporate merger sense, but in a very real sense, when GM owned 100% of Allison and all of their engineering was in-house American designs. Like my previous post on Detroit Diesels, this give some perspective when I point out that for 40 years, GM was the worlds largest business, with more engineers and resources than any other company on the planet.

Look at the intake system: Note how it is broken into four groups of three cylinders, just as the Corvair is set up as two groups of three cylinders (each head).  Look at how the incoming pipe is offset on each one of these groups, just as it is on the Corvair. This is not a coincidence, it is engineering. The Allison was originally designed to work well as a naturally aspirated engine just like your Corvair, and this is the proven way to get good mixture distribution at the rpm range we are speaking of flying. Keep in mind that these engines, and radials and Merlins were all “wet flow” engines where air and fuel were flowing through the intake, Just as we set up Corvair flight engines. This is different that modern cars that are only passing air through the intake, waiting to the last moment to inject the fuel. Although many WWII engines were injected, it is done way upstream by the supercharger.

Allison V-1710-109 V 12 Cylinder Aircraft Engine 1

Above is another overhead view of an Allison engine. Look at the layout of the intake pipes in the Vee of the engine and see that they are grouped in four sets of three with the off set in the feed pipe to each group of three. I didn’t invent this, but I am smart enough to copy it, and I am certainly smart enough not to say I know how to make specific improvement on engines I have never seen. Barring that, I know how to avoid having an email name with double meaning.

Image

Above is a good illustration of the Allison’s system. There is a giant myth that the Rolls Royce Merlin engine was a fantastic design and the Allison was a second-rate engine. This myth is held by people who love all things British.  (Yes I appreciate, MGAs, Triumphs, Rhona Mitra, and Led Zeppelin, But not as much as Corvettes, Buells, Raquel Welsh and Chuck Berry.) The Allison is an outstanding design. For Fans of P-51 Mustangs, go read up on F-82s and realize that the prototypes had Merlins, but the production planes, the ones that did 480 mph and shot down jets in Korea, had Allison engines.

Above, the EFI 2,700cc Corvair built by Mark at FalconMachine.net in 2007, at power on my dyno.  How do I know that header pipes and independent runners will not make the “15-20 hp” that “Toolmaker” claims? Because here is that test, actually done in reality, years ago, not on vapor ware or in the imagination of an internet personality.  Note that this engine is using headers with collectors. We also tested it with cast iron manifolds and mufflers. It has distributorless ignition. Six LS1 coils are mounted on the sides of the black airbox. After a lot of careful calibration runs, this engine achieved a 6 percent power increase over a Corvair running on a carb, it’s simple measured facts, but it also ignores the fact that such an exhaust fitted in a cowl will offer a lot of surface area for heat issues and weigh more, and it cost 2.5 times as much to build as a regular Corvair. (A plain old 2850 makes more power than this elaborate 2700. Displacement beats electronics and theory.) Because of the structural strength of the stock log was lost with the individual runners, this engine actually popped a head gasket on its first run. Mark later made thick reinforcement plates and welded them to the heads as stiffeners to do what the cast in log does.

Before questioning the test methodology or results, consider that Mark has earned his living with these systems for the past 20 years and the instrumentation included such niceties as a $500 laboratory grade digital oxygen sensor. Anyone who says that having an intake or exhaust change will make 15 -20 more horse power is just making their information up.

The internet will serve up a continuous stream of such experts who think that they can look at a photo and instantly improve 20 years of testing and development by 15 -20%. I am sure if you asked this guy, he would also tell you he knows how to make a Van’s RV-4 go 300 mph and how to make your car get 100 mpg.  People like this have never done anything to share useful information that gets rank and file homebuilders into the air with proven information they can count on. -ww