Sunday, April 9, 2017

Bing 64 (CV) Carburetor Part 3 (Idle Circuit) Sport Aviation / Experimenter "Technically Speaking" Article March 2017

Bing 64 (CV) Carburetor Part 3  (Idle Circuit)

March 2017 Sport Aviation Magazine

In Part 2 of this article, we talked about the starting carburetor (choke) system. We can run the engine at lower RPM settings only on the choke system, but as soon as we reset the choke system to the off position, the engine is now running on the idle circuit only. We often use this as a troubleshooting exercise. If the engine runs with the choke partially on, but dies as the choke is placed in the off position, it is an indication that the idle circuit is the culprit. It is absolutely essential that the idle circuit be set up and functioning properly. We use the idle circuit on every flight, and it is a surprisingly important system within the carburetor. Aside from the practical aspects of having a properly operating idle circuit, there are many correlations with the idle circuit malfunctioning and other engine problems, ranging from increased maintenance to engine stoppage and even engine failure.
If you follow our articles on a regular basis, you already have an insight into our underling premise that all successful troubleshooting, maintenance, and operation, comes as a result of  a solid foundation of the theory and physics surrounding the subject matter. With that being said, let’s dig into the theory of the Idle circuit.
With the slide (piston) completely closed, the vacuum present at the main fuel outlet is not sufficient to draw the fuel up from the main jet, through the mixing tube, needle jet, and into the diffuser and throat of the carburetor. At low power settings we need to supplement the fuel air system with an auxiliary fuel-air system consisting of an idling air jet, Idle jet, bypass, idle outlet bore, and an idle mixture screw. (Figure: 1)
Figure 1

Saturday, April 1, 2017

Bing 64 (CV) Carburetor Part 2 (Starting Carb) Sport Aviation / Experimenter "Technically Speaking" Article February 2017

Bing 64 (CV) Carburetor Part 2  (Starting Carb)

In Part 1, we examined the basic principals of operation of  the CV (Constant Velocity) carburetor. In this article we will take an in depth look into one of the most misunderstood subsystems of the carburetor, the “Starting Carb”.  It is often referred to as the “choke”, however, this  doesn’t properly describe the operation of the Starting Carb.  A choke is, really, a valve on the inlet side of a carburetor used to restrict the flow of air through the carburetor. This results in a low pressure with the intake manifold and carburetor system as a whole. This is different from the carburetor butterfly valve which is located down stream from the fuel nozzle which also restricts the airflow creating a low pressure, but only within the intake manifold. The choke valve which is located before the fuel nozzle presents a low pressure to the entire carb. This low pressure, naturally draws more fuel through the carb and into the intake manifold resulting in an enriched mixture. The starting carburetor, on the other hand, is in fact a separate carburetor within the larger carburetor. This starting carb provides for an enriched mixture by introducing addition fuel as well as air during the starting sequence. The starting carb on the CV carb is different from that incorporated into the slide type carburetors used on the Rotax 2 stroke engines. The (Bing 54) carburetors, used on the 2 stroke engines also use a starting carb, but it operates in an On/Off capacity. On the CV carb the starting carb operation is adjustable allowing for full application during start and cold weather operations, and the ability to reposition the “choke” for less affect as the engine warms.
Figure 1

Friday, March 24, 2017

EMG-6 "Shop Notes" March 2017

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

March 24, 2017

The elevator control horn being machined from .125 4130 steel plate.

Thursday, March 2, 2017

Syncmaster Rans Installation

This post will focus on the installation and testing of the Syncmaster throttle system that we have installed on our Rans S6 Coyote.

March 01 2017 

We begin the process of installing the Syncmaster throttle system with selecting a location to mount the Syncmaster.

For the installation of the Syncmaster on the Rans we decided to install it on the firewall. We chose to mount it in the radiator box as you can see in this photo.

Monday, February 20, 2017

EMG-6 "Shop Notes" February 2017

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

 February 20, 2017

After we finish welding the Polini 250 motor mounts we have to protect the tubes from corrosion.

Here you can see where we have removed the self etching primer before welding. This leaves the frame susceptible to corrosion.

We have also drilled pressure relief holes. These help prevent pressure buildup inside the tubes as we weld them. If the pressure is allowed to build up it can cause the weld to blow out.

Tuesday, February 14, 2017

Sync Master (Bill Stone)

Bill has volunteered to be our first out of house tester for the Sync Master throttle system for the Rotax 912 engine. This blog will be updated with information every time that he comes in to the shop. We installed the Sync Master throttle system on his Just Air Super Stol which has a Rotax 912ULS 100hp engine installed.


You can see the slack in the cable at the carburetor after 49 hrs of operation. Originally there was only a small amount of slack. It is possible this was simply caused by the new cables stretching a little. He still had a full stroke from idle to full throttle so this slack was of no significance to the Sync Master's operation.  

2017 National Aviation Technician of the Year (Press Release)

General Aviation Awards Committee Press Release

Brian Carpenter A&P/IABrian John Carpenter of Corning, California has been named the 2017 National Aviation Technician of the Year. Very simply, Brian has become the go-to guy when it comes to the construction and maintenance of—and education about—Light Sport Aircraft. Anytime he’s not teaching a Light Sport Repairman Workshop, you’ll probably find Brian in his hangar at the Corning Municipal Airport working on his Electric Motor Glider or creating an aviation educational YouTube video.
Brian has had a passion for aviation since he was a child, building and flying RC aircraft. In junior high, he progressed to building a self-launching glider out of homemade materials and started jumping off a small hill trying to fly. In 1979 he earned his pilot’s certificate while in the Navy. After graduating from Helena Vocational Training Institute (Montana) with his A&P mechanic certification, Brian worked as a lead mechanic for Aero Union, a large aircraft operation and maintenance company (now defunct) based in Chico, California. By 1985, he was the Chief Inspector, and was promoted to the Director of Maintenance by 1990.

In 1991 Brian opened his own aviation company, Rainbow Aviation Services, a full service FBO in Corning, CA, providing a variety of aviation services including: inspections, maintenance, flight instruction, test flights, and aircraft certification. The principal focus of Rainbow Aviation Services is Light Sport Aircraft. Rainbow's Light Sport Repairman Courses have been taught throughout the United States and Australia. The company is a source of LIght Sport expertise for aviation enthusiasts, flight instructors, mechanics and even FAA inspectors. Brian has mentored over 3,000 repairmen since the light sport rule was implemented in 2004, and is the only active provider of FAA-approved training for the Light Sport Repairman rating.

Brian has built 36 aircraft so far, and has become an innovative aircraft designer. His current project—the EMG-6, an electric motor glider—is a perfect example. Brian is developing a low cost, electric aircraft to meet the needs of the average person, making the aircraft affordable, and creating complete video instruction for the build. Another example of his innovative approach is that Brian has designed over one hundred 3D-printed parts for use on the EMG-6, and has written at length about optimal methods of 3D printing aircraft components.

Over the years Brian has given back to the aviation in community in myriad ways. He serves as an EAA Technical Counselor, presents workshops, forums and seminars for various aviation events, authors aviation educational articles and videos (including a monthly column in EAA Sport Aviation magazine), and serves as a volunteer technical expert for EAA’s Homebuilder’s Tips video series, just to name a few. Together with his wife Carol, Brian co-authored two books, one about ultralights and another for sport pilots.

Brian holds Commercial Pilot, CFI, Remote Pilot (drone), and A&P mechanic certificates, and a current Inspection Authorization. He is an FAA Designated Airworthiness Representative (DAR) and Designated Sport Pilot Examiner, holds a Light Sport Repairman Maintenance rating, and is a Rotax Authorized Factory Instructor. In 2006, Brian received the John Moody Award, the most prestigious award in Light Sport Aviation.

Wednesday, February 1, 2017

Bing 64 (CV) Carburetor Part 1 Sport Aviation / Experimenter "Technically Speaking" Article January 2017

Bing 64 (CV) Carburetor Part 1

This article will focus on the Bing 64 CV (Constant Velocity) carburetor. The basic principal of operation utilizes a vacuum operated slide  that varies the venturi size which, in turn, maintains a constant velocity of air passing through the carburetor at all engine power settings. The  advantage of  the CV carburetor is  that  it  supplies  the  engine  only  as much  fuel/air  mixture  as  the  engine  demands. For an aircraft applications, where we have large excursions in altitude, this is exactly what the doctor ordered. The Bing 64 carburetor (Figure: 1) has become, hands-down, the most popular carburetor used in the light sport industry. It is used on both the Rotax 912 as well as the 914. It is also used on the HKS 700 E, the Stratus, the Rotec Radial, and the Jabiru engines. This carburetor has a long history of great reliability, on a plethora of aircraft. 
Figure 1 The Bing 64 CV (constant velocity) Carburetor

Saturday, January 28, 2017

EMG-6 "Shop Notes" January 2017

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

January 30, 2017

For the last 16 days straight we have been engaged in a light sport repairman maintenance class.  This is one of the smallest classes that we've ever had. Four of the students that signed up for this class had to pull out for various reasons just before the start of class. The wintertime classes are always limited to  a maximum of 12 to accommodate the facilities during the cold winter months. As it turned out the best day, weather wise, of the entire class was the last day. All of the students graduated with flying colors and will now move on to utilize their FAA light sport repairman maintenance certificate in different ways. Although this was a small size class of only 8 students, they came from pretty much every corner of the United States. And unlike a normal class, we had no foreign students this time. The next class will be in May and is already starting to fill. This is the 1st class that we have taken the class photo with a drone.

Brushless DC Motor (How it Works) Videos

Brushless DC Motor (How it Works) Videos

Sunday, January 22, 2017

Low Cost Hydroforming (Video)

Low cost hydroforming on the Rainbow Aviation Video channel with your host Brian Carpenter. In this episode were going to be taking a look at a low cost way  to manufacture your own aluminum hydro-formed  parts. This is a companion video for technically speaking article published in the May 2016 sport aviation magazine

Saturday, January 14, 2017

Dan Kokenge Design

An email came across my desk today. Thought I'd share it. Innovative ideas going all over the place these days.

January 26, 2017

Wow! I saw your video. I thought I was the only one working on this. 
I agree that electric is the way to go. The military has pretty much said that all new craft will be electric.

Tuesday, January 10, 2017

Lift Strut Attach Fitting (Video)

53-10-50 Lift Strut Attach Fitting Video

In this video we go through the installation process of the lift strut attach fittings on the fuselage frame.

Monday, January 9, 2017

Seat Support Tubes (Video)

Seat Brace Tube Installation

P/N 53-10-02-106  and P/N 53-10-02-107 Tube installation onto the fuselage frame.

Sunday, January 8, 2017

Ultraflight Batteries Donald Lineback

 "Donald Lineback" Batteries

  Donald Lineback and his latest E-Mail.

 January 7, 2017

  News about what to buy: 

 Before looking at batteries - consider the voltage current demand. Let’s compare voltage to gasoline. One gallon of gas contains 33.7kWh energy according to EPA or 33,700Wh. How big of battery would that be? An NCM Lithium-Ion pack would be 33.7kWh, 172 cells, 635v, 107Ah and weigh 927 pounds. If you factor in the fact that the average car only gets 23% of that energy - the battery pack would still weigh: 213 pounds. So adding a big current demand is not good. Nor is it a good idea to equate the battery pack weight to 5 gallons of fuel in ultralights. ("apples to apples”)

For the number one incentive was to build a highly efficient motor and use less energy. It has been easy for some motor designers to make high kW demanding motors. The problem - airplanes just couldn’t carry enough batteries. Big motors also disqualify themselves to be used with solar and other power supplies like fuel cells. 

What is the best battery and what on the “drawing board?” As for the future - higher energy batteries can be made, but they are only good for 3 or 4 charges and need to be scraped. The batteries that Tesla has been using, sourced from Panasonic, for its Model S electric cars are mostly likely a lithium-ion battery with a cathode that is a combination of a lithium, nickel, cobalt, aluminum oxide. The battery industry calls this an "NCA battery" and they've been around - and made by Panasonic, LG and Samsung - for many years.

Typically, lithium-ion NCA batteries use a combination of 80% nickel, 15% cobalt and 5% aluminum. (The anodes in these traditional lithium-ion batteries is usually a graphite combination, which acts as a host for the lithium ions.) The addition of the aluminum to the NCA battery makes it more stable.
For a home battery grid - Musk said that Tesla will use a lithium-ion battery with a nickel, manganese, cobalt oxide cathode called an NMC (or NCM) battery. Many traditional NMC batteries use one-third equal parts nickel, manganese, and cobalt.

Where do we stand among all the choices? NCM still reigns as king for safety and it works great for cars that handle the slight increase in weight. We have found a new source for the NCA which offers the weight savings needed in aviation. As soon as we have all the numbers - they will be posted on our website. Our new motor has an advantage because with a slower charge time, lower discharge demand and our new Active BMS - the safety went way up. 

Here is some info to help in your calculations:
Note: 1kW = 1000W. To find Ampere hours - Watt hours ÷ Voltage.  
kWh (1000Wh) is unit to measure total energy stored in battery and it can be calculated as battery voltage multiplied by Ah (V*A*h = Wh). In general kWh is unit to measure energy used.
Voltage is similar to water pressure like the height of the dam or water tank.
Current is the flow-rate of water.  
A battery rated for 100 amp hours will provide 5 amps for 20 hours.
If we have a 12 volt battery, we multiply 100 by 12 and determine that the battery will provide 1200 watt hours.
To apply the metric ‘kilo’ prefix, we divide the result by 1000 and determine that the battery can supply the 1.2 KW hours.
In the case of our 1200 Watt Hour conversion, we need to understand that what is really being said is that the battery will provide 60 Watt Hours for 20 Hours.

Sunday, January 1, 2017

Top 10 apps for the aircraft builder. Sport Aviation / Experimenter "Technically Speaking" Article December 2016

Top 10 apps for the aircraft builder

“There’s an app for that.” This overused cliché becomes more and more apropos every day. Even for the aircraft builder, we now have a virtual toolbox in our pocket that has become indispensable. We have reached the point in technology where it is now the norm for an aircraft manufacturer to publish maintenance manuals, parts manuals, and all other documentation, for that matter, in a digital format. If you’ve grown up on paper, the transition to digital can sometimes be difficult, but the rewards are well worth the effort.

#1 The PDF Reader App:(Figure: 1) The Rotax manuals, for example, consists of literally thousands of pages spanning more than a dozen different manuals. The ability to use a search function on a 500-page manual can really speed up the process of locating the information that you’re looking for. In our shop, we have a library of aircraft maintenance manuals accumulated over the last 40 years.