Plenum, Oil Cooler Duct & Upholstery

My poor plenum tops have taken a beating with my oil cooler installation and then relocation. It was a shame to screw up my checkerboard paint, but it’s all in the name of progress, right? After grinding out all the previous ducting I had to re-glass the holes near the inlets. I used clay as a backing and then glassed the holes shut.

The lower half of the new duct to the oil cooler is attached to the cylinder baffles. As you can see, the cylinder baffles are held on with safety wire. I put a couple of nutplates in the lower duct that the top duct will attach to. The gap will eventually be filled with a neoprene ring. I needed a little space because there will likely be movement between the engine and the oil cooler (because the cooler is mounted to the engine mount).

The plenum is in place and completes the new duct to the oil cooler. With all the screws in place, it’s really a solid setup.

Here’s a birds-eye view of the engine compartment as it currently stands. You can see the patches towards the inlets where I removed the previous ducting. I used duct tape to seal the gap in the new plenum for now. Once I know the system is going to work, I’ll fabricate a neoprene sleeve for the gap.
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I went up on Wednesday of this last week to test the new installation. I ran the plane wide open for 30 minutes to see how high I could get the temps In the old days, I could easily flog it into going to 225 degrees. I’m happy to say that the best I could do running around at 3000+ rpm for a full 30 minutes was 210 degrees. I have no intention of running around at 3000 rpm in normal operations so I’m calling this a success.
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I de-cowled the airplane after the flight and found 2 small oil leaks. The first was an easy one… in fact it was one of those “duh” moments… The hose on the breather port was night tightened down. Woops.
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The second leak came from my modified reducer fitting on the right side (looking at it) of my oil filter adapter. I remember being excited to see if the modified adapter was going to solve my clearance issue so I put the fitting on without using the Permatex teflon sealer. It leaked. Woops again. I stopped by the hangar last night at about 9pm on my way home from work and fixed both these issues in hopes of flying to breakfast this morning.
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The other thing I did yesterday was that I picked up my new seat cushions with the new upholstery. A guy over in Brighton, CO built the seat cushions and did all the sewing, too. I could have picked from any material in the world for my upholstery, but ended up picking sheepskin. I purchased 2 pelts from Colorado Sheepskin Factory in Denver.
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I was originally planning to go with a dark grey color, but nothing I found really blended well with all the other colors in the interior. I ended up going with black because black seems to go with everything. Now that it’s installed, I’m very happy with the look.
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I went out to the airport today (Friday) with hopes of flying over to Greeley (KGXY) for breakfast. Unfortunately, by the time I arrived at the airport at about 7:30 this morning, the wind was already blowing in a direct crosswind at 16 knots. It would have been do-able, but I figured I’d get my fanny kicked all the way to and from Greeley so I decided to stay on the ground and work on the next project.
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What’s the next project? Stay tuned for pictures and a narrative in the next entry.


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