Mixed emotions,

Let'sgoflying!

Let'sgoflying!

Touchdown! Greaser!
Joined
Feb 23, 2005
Messages
20,819
Location
west Texas
Display Name
Display name:
Dave Taylor
every time I find a problem.
"%$#8 there goes another $_____!!" :mad:
"Well, at least it didn't cause a prob over the mountains, during last week's night flight!" :eek:
Spot the defect:
itll be a little shocking when I post the second picure.
 
OK, Dave, at least tell me what it is I am looking at (said the nimrod, scared to death because he really wants to buy an airplane).
 
Let'sgoflying! said:
every time I find a problem.
"%$#8 there goes another $_____!!" :mad:
"Well, at least it didn't cause a prob over the mountains, during last week's night flight!" :eek:
Spot the defect:
itll be a little shocking when I post the second picure.
Click to expand...

The problem is obvious - theres a big hole in the bottom of that...uhhh....thing. Big circle one, right in the middle.
 
Let'sgoflying! said:
Spot the defect:
itll be a little shocking when I post the second picure.
Click to expand...
Bad camera angle? Looks like rivets in hinge are deformed or missing. What goes on the other side of the hinge?

I too am not certain what I am looking at but I suspect it is part of a duct or air box.
 
sorry its a sheet aluminum air filter housing. The top cover is removed. The bottom has a round hole for the air inlet from the inside of the filter. The top of the pic is the open end where air is admitted to the filter. The hinged thing is the automatic alt air door. The filter is an oval shape and sits in this box.
 
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It looks like a big crack coming out from the alt. air door hinge. Looks like it runs along the right side at the formed corner and maybe even up the right side all the way through the flange for the lid as well as into the round hole I assume is the inlet to the carb. Question is how close was it to swallowing a bunch of aluminum parts.:no: :no:
Wish the photo had better resolution.
What is the prize Dave, lol
Don
 
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Last guess for me: the upper right support tab is bent at a 90* angle.
OR,
the upper left fastener retainer is not aligned to the long axis of the box which caused an alt air source.

EDIT: I saved the pic to wallpaper and looked intently at the enlarged pic. Disregard the bent tab guess, it was an illusion. The fastener retainer shouldn't be too much of a problem. Other than it being the wrong box for your bird I really don't have a clue.........
 
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Let'sgoflying! said:
sorry its a sheet aluminum air filter housing. The top cover is removed. The bottom has a round hole for the air inlet from the inside of the filter. The top of the pic is the open end where air is admitted to the filter. The hinged thing is the automatic alt air door. The filter is an oval shape and sits in this box.
Click to expand...

The oval filter sits inside this box inside the oval formed by the 4 tabs?
If so, it looks like the hinge opens inward, into the filter material. I'm thinking it's not going to open very far if at all. That can't be good if your normal air supply is cut off.
 
Here. It did not take anything unusual to separate these two parts.
Watch for pic of repaired part this weekend, I am hunting down rivets right now.
 
Looks like a classic case of vibration induced fatigue. Chances are if you patch it, it will break again soon, BTDT. Best would be to have someone "rebuild it" with all new sheet metal.
 
Let'sgoflying! said:
Here. It did not take anything unusual to separate these two parts.
Watch for pic of repaired part this weekend, I am hunting down rivets right now.
Click to expand...
I was right!!! There were fatigue cracks. I knew it I just didn't post that I knew it.:dunno:

lancefisher said:
Looks like a classic case of vibration induced fatigue. Chances are if you patch it, it will break again soon, BTDT. Best would be to have someone "rebuild it" with all new sheet metal.
Click to expand...
Any HS kid worth his beans could make one of those in shop. Have him make two, get the A&P to sign off, and install the modified box. Lance is right, rivets in bad metal in a weak design = failure.
 
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lancefisher said:
Looks like a classic case of vibration induced fatigue. Chances are if you patch it, it will break again soon, BTDT. Best would be to have someone "rebuild it" with all new sheet metal.
Click to expand...

Thats the plan.

I am hoping that after rebuildng it, it'll last another 38 years... maybe I will use the next thicker gauge sheet stock. (can't see any downside to it at first glance) Its just a 8x11 flat sheet with some holes in it.

I can't tell you how glad I was to discover it... I was cleaning and inspecting plugs & injectors - got around to looking at the hoses off the accessory case & nudged the box, and was shocked to see it slip right off. Had it vibrated to the side, I can imagine it partially blocking the air inlet below.

I can't figure how folks never take the cowl off except at annual time! So much vibration, heat, airflow and in general, deterioration happens there. I try to do it every 30 hrs and have found a bunch of scary stuff over the years. Mostly unpredicable stuff now that I am more aware of the typical weak spots.

I think I had the pic resolution 'just right'... some of you were able to see it but not all of you!
 
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