Lycoming 0-235 L2C

Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Sep 03, 2020 11:49 am

Hey Guys ,
With 30 small Dzus in hand , I'm nailing the lid shut ...
Once I have it locked in , I can trim closer .
One side has the fasteners .
I still need to lay-out the other side, they aren't the same because of the "split" side pieces are offset.
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Gotta Fly...
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PS I was hoping for a smooth polished finish ...Hmmm I may have to do the engine turning on the cover , it looks ruff
I think this is a light plenum...
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2019 Baffling (179).JPG
2019 Baffling (180).JPG
2019 Baffling (181).JPG
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and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Dec 16, 2020 1:40 pm

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Hey Guys ,
I bought 3/16" Dzus fasteners ...oval head ...and matching spring .

In order to install them , I had to remove the plenum and re assemble it on the bench .
Attachments
2019 Baffling (186).JPG
2019 Baffling (187).JPG
2019 Baffling (192).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Wed Dec 16, 2020 1:59 pm

Hey Guys ,

I made two jigs for spring mounting ...

One , was standard spacing .
The second was "off set".

Seems like a couple of my holes were just a pinch close to some flanges.
I used the off-set to correct it ....then, the center hole gets drilled to 3/16" and the off set disappears .
nobody knows .

Oh, The 10" KNIPEX.... I really like this tool . I use it mostly for rivets .
Duct taped a nut on it to jump a flange .
.
Gotta Fly...
.
Attachments
2019 Baffling (193).JPG
2019 Baffling (198).JPG
2019 Baffling (199).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Dec 17, 2020 9:02 am

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Hey Guys
.
I got all the springs in place.
Notice the Popsicle sticks ...
The Plenum cover will get a Chaffing pad/ Seal
The space can also be fine tuned by adjusting the Dzus spring for more or less tension .
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At final ... I will check every Dzus for Clearance and Proper spring "lock"
Right now it's built with minimum clearance(3/16") , it helps during fab work , tighter tolerances .
Two reasons I need to re drill the center holes .
One , it makes it easier to get the Dzus in and out of the hole .
But more important , Heat...expansion and contraction ( not to mention vibration )
.
Gotta Fly...
.
Attachments
2019 Baffling (200).JPG
2019 Baffling (202).JPG
2019 Baffling (205).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Fri Dec 18, 2020 9:59 am

Hey Guys ,
.
I took out a lot of the tool marks / groves ...
.
I still need to trim the cover edges .
I'm not sure just how I will 'BLING' the surface ...
it needs more clean up before I can do anything .
.
Gotta Fly...
.
Attachments
2019 Baffling (206).JPG
2019 Baffling (207).JPG
2019 Baffling (209).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby Clark in AZ » Fri Dec 18, 2020 1:42 pm

Looks awesome! Great job!

Clark
Building SuperSTOL Kit 512
Cave Creek, AZ
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Thu Dec 24, 2020 11:07 am

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Hey Clark , If you hold a tool long enough , something is bound to happen .
Sometimes I hold it too much ... Then its all about salvaging what you can ... if you can .
Or back to the drawing board .
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I'd call this cover a Salvage ...
.
My next move would have been filling the inside with foam ,
and making a carbon fiber cover .
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I did reach some goals ... comes apart easy ...One screwdriver is all you need ......and it's light .

But .... will it be able to take the stresses involved ...heat , vibration ...I'll need to watch it
.

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Still messing with it ...More cleanup and chaffing material needed ...( I'm thinking about the Natural Wool I bought )
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Ho ho ho

Gotta Fly...
.
Attachments
2019 Baffling (210).JPG
2019 Baffling (211).JPG
2019 Baffling (214).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby Clark in AZ » Thu Dec 24, 2020 11:25 am

LOL! I know it would be really expensive, but I think carbon fiber would be the way to go. MUCH stronger/stiffer, lighter, and would have the cool factor too! :)

Clark
Building SuperSTOL Kit 512
Cave Creek, AZ
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Dec 28, 2020 11:29 am

Hey Guys,
.
Cleaning it up "prepped" it for the swirls ...Engine Turning
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Got it laid out ...This sprays a little black WD40 , So I need to set-up where I can catch it .
I'll need to blend in the edges , sometimes I make the swirl section by hand ...just make it blend .
Not all swirls are perfect , in fact , my technique puts most of the swirl at 10:00 and 4:00 , the rest gets covered in the design . ( 10 & 4 when I go right to left , my preferred direction )
If you make a full swirl ...next row you'll have to work at swirling through the scratches from the upper swirl .
This is a busy design , should hide fabrication scars .
.
Gotta Fly...
.
PS So Left to Right... would be 2:00 - 8:00 for the main swirl area, everything else gets covered
Attachments
2019 Baffling (216).JPG
2019 Baffling (219).JPG
2019 Baffling (222).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Tue Dec 29, 2020 5:35 pm

Hey Guys ,

Since I get asked about doing this style ...I'll try to get pictures during the process .
FIRST ... before marking the grid , I wiped it down with Lacquer thinner .
Otherwise you'll rub off the lines .
Where the pattern crowds my 2" pad , I fake the swirls with a piece of sandpaper.
Tickle the eye ...There's another insight to her name "Miss Tickle Madness" (Mystical Madness)
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Gotta Fly...
.
.
Attachments
2019 Baffling (223).JPG
2019 Baffling (224).JPG
2019 Baffling (225).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Fri Jan 01, 2021 10:21 am

Hey Guys ,
Here's some close shots of "patching" the pattern ...
The 2" scuff pad isn't able to make the swirl ...
I also tried a piece of thin stainless steel to protect the opposing pattern , No Joy

So... Sand paper in hand ... I pressed on the pivot point / center of the swirl ...
I drag the sand paper across like a compass makes a circle ...repeat until tickled .
.
Later , when things are cleaned up and polished ... I'll take more pictures of the same area to compare .
another spot I have been touching up is center of a lot of swirls in the rows , because of the rough surface , the pad just doesn't push in ....
With one finger at the center(with sand paper) ...A quick twist and the swirl is complete .
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The swirls on my firewall didn't get this added touch up , but the pattern is so busy , its hard to tell
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Hiding scratches and dents with more scratches .
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Gotta Fly...
.
PS... My point of these close-ups is to show just how crappy sloppy this can be.
I think what discourages people who try this is not seeing the bigger pattern ... looking too close at each swirl ..
Just keep going and look at it when you are done .
If the swirl didn't end up centered where you wanted , push down and lift again ...it will move .
LOOK at how many swirls need to be done ...You WILL get better with that much practice .
Attachments
2019 Baffling (230).JPG
2019 Baffling (227).JPG
2019 Baffling (228).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Mon Jan 04, 2021 9:07 am

.
Hey Guys ,
In the first picture you can see the next swirl needs to be done by hand .
Look at the others from previous rows , those were by hand .
Later ....After all the patterns are in place , Polishing will kill the coarse lines from sand paper .
.
It sure hides / Blends ... Future scratches are hidden also
.
Gotta Fly...
.
.
Attachments
2019 Baffling (234).JPG
2019 Baffling (235).JPG
2019 Baffling (236).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Tue Jan 05, 2021 7:22 am

.
Hey Guys ,
Got one side done .
Time out ...
Its a warm day in January , I better bring more wood to the house and cabin ...
I made some pallets with 10ga wire mesh.
I lay the wood like a roof , it sheds water while outside and vents good too .
I put one by the back door at the house , it has side covers and a lid to keep the weather off.
The one for the cabin used to be outside ...no cover ( No Joy )
I thought I would sacrifice a little shop space and start putting it "IN" the cabin...
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Back to work ...
I checked the layout , the sharpie held up good .
I put a dot where each of the swirls are centered ...
And this side will run Left to Right ...
.
Gotta Fly...
.
.
Attachments
2019 Baffling (242).JPG
2019 Baffling (243).JPG
2019 Baffling (244).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Re: Lycoming 0-235 L2C

Postby planecrazzzy » Tue Jan 05, 2021 9:14 am

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Its cleaned up , I need to polish it a little
.
Gotta Fly...
Attachments
2019 Baffling (245).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Re: Lycoming 0-235 L2C

Postby norristailwind » Wed Jan 06, 2021 1:43 am

That looks really good, like all of your work. I'm curious to see how you "polish it up" - I've always stopped after the engine turning.
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