Backcountry Pilot • Lycoming O-540 making metal+2012 Annual update

Lycoming O-540 making metal+2012 Annual update

Lycoming, Continental, Hartzell, McCauley, or any broad spectrum drive system component used on multiple type.
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Thu Feb 23, 2012 3:59 pm

Re: Lycoming O-540 making metal.

OregonMaule wrote:So here in Madras doing the annual on 1 Tango Lima. Got 50 hours on the O540. I found a small gas drip out of the drain plug on the carb. The knuckle head who installed it, cross threaded it. Now the carb has to come off and get replaced. Good news PAE is replacing the carb under warranty.
Bore scoped the muffler flame tubs last year all good, they had 250-300 hr on them. Now 450-500 the mufflers are shot, no real surprise. Flame tubes are $100 a side I think. If I go back to Maule mufflers I will put in new flame tubes every year!

I am going to buy the Tims Aircraft Exhaust system. $2800 OUCH!!!

I understand a lot of aircraft will go TBO on exhaust. Really disappointed that Maule has known about this for ever and won't fix it. That IMHO is BS!!

Other than that 1 Tango Lima looks good.

Alex was on his way to Seattle, driving and stopped by to say hi.

Cheers...Rob



What kind of fertilizer you using on your money tree?

OregonMaule :D
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Glidergeek :(
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Thu Feb 23, 2012 6:54 pm

Re: Lycoming O-540 making metal.

Glidergeek wrote:
OregonMaule wrote:So here in Madras doing the annual on 1 Tango Lima. Got 50 hours on the O540. I found a small gas drip out of the drain plug on the carb. The knuckle head who installed it, cross threaded it. Now the carb has to come off and get replaced. Good news PAE is replacing the carb under warranty.
Bore scoped the muffler flame tubs last year all good, they had 250-300 hr on them. Now 450-500 the mufflers are shot, no real surprise. Flame tubes are $100 a side I think. If I go back to Maule mufflers I will put in new flame tubes every year!

I am going to buy the Tims Aircraft Exhaust system. $2800 OUCH!!!

I understand a lot of aircraft will go TBO on exhaust. Really disappointed that Maule has known about this for ever and won't fix it. That IMHO is BS!!

Other than that 1 Tango Lima looks good.

Alex was on his way to Seattle, driving and stopped by to say hi.

Cheers...Rob




What kind of fertilizer you using on your money tree?

OregonMaule :D
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Glidergeek :(
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58skylane tree :cry:
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Thu Feb 23, 2012 10:17 pm

Re: Lycoming O-540 making metal+2012 Annual update

You guys are lucky, I can't even get mine to sprout! :(
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Thu Feb 23, 2012 10:20 pm

Re: Lycoming O-540 making metal+2012 Annual update

Jaerl wrote:You guys are lucky, I can't even get mine to sprout! :(


I'm really sorry, Jerry. No offense, but that made me laugh! :lol:
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Thu Feb 23, 2012 10:24 pm

Re: Lycoming O-540 making metal.

58Skylane wrote:What kind of fertilizer you using on your money tree?

OregonMaule :D
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Glidergeek :(
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58skylane tree :cry:
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Gump tree.... Run Forrest Run. :lol:

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Gump
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Fri Feb 24, 2012 12:50 am

Re: Lycoming O-540 making metal+2012 Annual update

Rob,
If you fly up to Tim's place you'll enjoy the strip. Its a pretty cool little spot.
Say HI to Tim for me.

Dave
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Fri Feb 24, 2012 11:01 am

Re: Lycoming O-540 making metal.

GumpAir wrote:.....
Gump tree.... Run Forrest Run. :lol:
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Gump


You're cracking me up!
This one looks like a baby ent (lord of the rings) looking for his mama.
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Fri Mar 02, 2012 2:23 pm

Re: Lycoming O-540 making metal+2012 Annual update

Well, Rob...looks like I'm joining the flame tube club. Both sides shot! Only about 3 inches of baffling left on one side.

:-P
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Fri Mar 02, 2012 2:35 pm

Re: Lycoming O-540 making metal+2012 Annual update

I think on the exhaust for the Maules is just life! I had to replace mine at about 1600 hrs.
When I had all the 520's in the 206's and 185's we had a continual send out about every 500 or so hours for the mufflers to be rebuilt or replaced !
If you use them steady I do think they last longer, but I don't think the stock ones will ever make the life of the engine!
My $.02
GT
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Fri Mar 02, 2012 4:28 pm

Lycoming O-540 making metal+2012 Annual update

260Driver wrote:Well, Rob...looks like I'm joining the flame tube club. Both sides shot! Only about 3 inches of baffling left on one side.

:-P

If I ever go back to Maule mufflers I will put flame tubes in every year! Mine were in at 400 hr at 450 they were gone.
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Fri Mar 02, 2012 4:38 pm

Re: Lycoming O-540 making metal+2012 Annual update

Where do you guys run your temps, lop or rop?
GT
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Fri Mar 02, 2012 9:03 pm

Re: Lycoming O-540 making metal+2012 Annual update

I run LOP almost exclusively...resulting in higher EGTs, of course, but the CHTs are good and low. I suppose the EGTs could be responsible, but we are talking less than a 10% increase in temps (1400-1500) for about a 25% reduction in CHTs (400-300)...ballpark on those numbers, for the sake of discussion.

That said, I've only put 100 of the 750 total hours on my bird and who knows what condition the flame traps were in before I got it?

I'm no metalurgist and by no means a Maule expert, but from what I've read EGT values are insignificant when compared to CHTs...and the Maule exhaust design just plain SUCKS!

Then again, I'm still learning, and if anyone has advice which could end up saving me money in the long run, I'm all ears!
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Fri Mar 02, 2012 10:00 pm

Re: Lycoming O-540 making metal+2012 Annual update

M6RV6 wrote:Where do you guys run your temps, lop or rop?
GT

I'm carbureted so no LOP. When I put the overhauled engine in we checked the flame tubes and all intact. They must of been ready to go. The first 20 hours I was full rich <1400 the next 20 hours I was 150 ROP 1400 EGT after that 120 ROP 1430 EGT My max EGT is 1550

The real problem is right after the flame tube goes the outside can warps. I won't use it if that happens. If that fails your on fire. Outside burns through the cowl. Inside blows on the carb, I really don't like that. It seems like 400-500 is typical life of these mufflers.

Good day
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Sat Mar 03, 2012 8:48 am

Re: Lycoming O-540 making metal+2012 Annual update

I had an outfit down in El Cajon CA overhaul my muffler: Custom Aircraft Parts 800-561-1901 www.customaircraft.com They had OH'd a hangar neighbor's entire exh system & he raved about them. I was very satisfied with their work-- quick turnaround, high quality, & reasonably priced. My Avcon muffler had an AD (applicable in real life, but not technically-- long story) for the muffler body cracking where the tailpipe welds on, due to using too thin a material. They rebuilt this piece using heavier material. Turned out great. Give them a call before sending yours off to someone else.
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Sun Mar 04, 2012 1:35 am

Re: Lycoming O-540 making metal+2012 Annual update

Tim @ Tim's Aircraft has a nice system available. I've been very pleased.
253-857-3642.
There are quite a few Maule drivers on this site with his system.
Chaz
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Sun Mar 04, 2012 8:05 am

Re: Lycoming O-540 making metal+2012 Annual update

Chazdevil wrote:Tim @ Tim's Aircraft has a nice system available. I've been very pleased.
253-857-3642.
There are quite a few Maule drivers on this site with his system.
Chaz



I pick my system up from Tim tomorrow. Chaz how many hours and years on your system? Any problems?

Thanks Rob
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Sun Mar 04, 2012 8:28 am

Re: Lycoming O-540 making metal+2012 Annual update

Yeah, I spoke with Tim yesterday...sounds like he has pretty good system. Unfortunately, that money tree I planted has not blossomed yet.
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Sun Mar 04, 2012 8:42 am

Re: Lycoming O-540 making metal+2012 Annual update

260Driver wrote:Yeah, I spoke with Tim yesterday...sounds like he has pretty good system. Unfortunately, that money tree I planted has not blossomed yet.


I think I have picked my money tree so much I killed it.

Buy 2 extra flame tubes they are 88 bucks each. Change them every 200 hours!!!!! Keep the EGT around 1400 no LOP Check the can for warping replace if it shows any. You don't want an inflight failure.

Cheers
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Mon Mar 05, 2012 5:28 pm

Re: Lycoming O-540 making metal+2012 Annual update

I've got only about 275 hours on mine. This is over about 2.5 years. Not exactly long term use for sure. George Kirkish (sp?) on Vashon Island has been flying with them for quite a bit longer.
I've not had any trouble.
Chaz
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Mon Mar 05, 2012 11:33 pm

Re: Lycoming O-540 making metal+2012 Annual update

Hey Chaz, talked to Tim today when I picked up my system. Sounds like you have a very trick plane!

I am excited to get the new exhaust on and see how it sounds and works. Had to go right by Cabela's on the way so naturally had to stop and buy something. :D

The carb should be back Wednesday or Thursday. One day to put it together and I should be good for a year.

Cheers
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