Inlet manifold and Decompressor

[Neil Spooner]

Hi Guys,

In the constant search for the perfect Nipper (!!) I have a couple of ideas:

The oil cooler inlet manifold is not a new one, but I have an idea that I could do with some machine shop access to develop, does anyone have such access? particularily a milling machine for aluminium. (Peter Bentley! are you out there somewhere?)

The other idea is a decompressor so that an air-start would be achievable without having to dive to Vne to get the engine turning (thats for us VW owners!)

The Nipper is going well, hope to do the flight test this week so I can get my permit, and thence to the skies!

All the best,

Neil

[G-NIPR]

Hi Neil,
I am particularly interested in the decompressor idea, and have been talking to engineers about this for a while.
Please let me know if you progress with it...
Thanks.

Paul.
G-NIPR.

[Neil Spooner]

Hi Paul,

The idea has been on my "drawing board" for a while, I may be able to get a 2nd hand 1600cc aero version VW to experiment with, just waiting on a price. I have run the idea past Andy Draper, he is very much in favour of it, so it has his initial support.

Nipper going well, tho' I landed on a short down-hill tarmac runway Sat' and used the brakes quite hard, the result is a pair of distorted discs. The thin stainless just is not up to the job for stopping the aircraft, they are only really good for engine run ups and parking. I still have a pair of new ones, so they will go on today. I need to research some hydraulic bicycle discs to fit.

Hope all is good with you, I am looking forward to a Nipper meeting some time!!

Neil

[OO-WBR]

Anyone going to the Air-Britain fly-in at North Weald?

Would be nice to see some Nippers there

Willem

[Pat Blenkinsopp]

Greetings Neil and anyone else on the forum.

Re Bicycle Hydraulic brakes. Mine work REALLY well but I did have trouble with distorting discs after a hard application. I cured this by making some new discs from 1mm 4130 steel. The extra thickness did pose a problem with the brake units clearance but some judicious fileing cured that. The new discs work superbly and will hold ASXI on tarmac at full throttle. I have landed and rolled to a stop on grass using hard braking in a paced 75 mtr. That performance pleased me a lot !!!

The post rebuild test flight (last Sun) went very well indeed. Landed after 35 min.3 touch and goes and a selection of stalls etc. The sustained 5 min climb was great. From 1000 ft I got to 6040 ft and the temps and pressures were on the numbers (over cooling if anything) OAT 27 degC. Oil pressure steady as a rock.

Owing to a misunderstanding between my inspector and the LAA, I have to go and do another test flight with a dive to VNE plus 5% because of aerodynamic mod installed (Fin /Ruddeer).

I hope to get some photos posted when my geek son can show me how to do it .

All the best,
Pat ASXI

[Pat Blenkinsopp]

Willem,

Yes to the air britain gig if I get my permit paperwork back in time,
Pat
ASXI

[Neil Spooner]

Hi Pat,

The part no's and source of your brake system would be much appreciated.

Great to hear you are up and running again, I would be interested in flying down next week in mine to take a look, where are you based now and would it be convenient?

Neil

[Neil Spooner]

Hi Pat,

Just a thought........have you calibrated your ASI? It would be a shame to dive to Vne+x% !! I had no problems with mine, but it's a scary part of the envelope.

Neil

[Pat Blenkinsopp]

Greetings Neil

The brakes were sourced from Raymonde Cuypers in Belgium. In retropect I would do a bit of Googleing for bike brakes and make up the various brakets myself. I paid 500 euros for mine which was porbably a bit over tyhe top. If you need details of the various fittings etc I will be happy to forward them to you

Incidently the brakes I use are Magura units which seem to be a good choice because they seem to be fairley substantial and slightly more meaty than some of the shimano and other ones.

Just let me know of any details that youy want and I will send photos and drawings ect

This is a great mod that WORKS

Please get back to me with your requirements

All the best

Pat G-ASXI.

[Pat Blenkinsopp]

Neil,
by the way my ASI has been calibrated and found to be within 2%.
Ithink I am OK on that one.
all the best
Pat

[Neil Spooner]

Hi Pat,

Good luck with the Vne test, hope all goes well.

Re' the brakes, the only thing that makes me sweat is dealing with the LAA and the aircraft down time while the paperwork is sorted!!
I have got some Magura hydraulic brakes from a bike, and have made the brackets, but not yet tried or tested them. I am interested you have used 4130 for the discs, how did you machine them up? How are they holding up to corrosion?

Neil

[Pat Blenkinsopp]

Greetings Neil,

I chain drilled the discs and thence used a large disc sander and mounted the disc on a rotatingply bed (adjustable and simply spun them round very slowly to get them te right diameter. In retrospect I would lathe them up for any future discs. Regarding corrosion, I masked up the portion that the pads contact and simply etch primed and two pack top coat.they seem to be holding up OK.
Be very careful with the bolts that hold the discs/wheels together. The extra thickness of the new discs takes the nuts into minimal saftey. I simpley milled out the thicker discs by a few thou and used some half washers where the bolts go through.
Hope this is of use

All the best
Pat