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| OS 4st Engine Repair |
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| Joules:
I did this repair a few years ago, but happened on the photo's I took whilst looking for something else :scratch: The plane had crashed and ripped out the exhaust manifold. First job after getting it cleaned in the ultrasonic bath was to mount the head on a lump of something I could grip and act as a heat sink when I did the repair. Once mounted I could clean up the damaged areas and prepare the casting for alloy welding/soldering. I jammed a thermocouple in the part as I did the weld to monitor how close I got to melting the casting as a fraction too much heat from the blowtorch would cause the whole casting to slump and melt. I used plaster of paris for dams around the casting and in the exhaust port so the molten metal stayed where I wanted it and played the torch around the casting rather than just at the port. The above picture is after I re-machined it ready for thread cutting, you can see some porosity in the metal I added. Part re-threaded and cleaned up. The welding process burned all the gunk off and left me with a lovely clean part. I didn't have a means to cut metric threads at that time so the thread cutting was done on a friends lathe. Finally back together and you could hardly tell it had been repaired from the outside, just cleaned it up with a needle file. I was happy with the repair and so was the owner who had this engine flying again. This was the first time I had really used the alloy welding rods in a real application so pretty impressed. Didn't work so well on the next engine I tried to repair, and of course didn't bother taking photos that time... :palm: Joules |
| Stilldrillin:
Repaired, as new, Joules! :bugeye: Very well done! :thumbup: :clap: :clap: David D |
| vtsteam:
Yes that's pretty tricky work! :thumbup: :clap: |
| Meldonmech:
Hi Joules, That is a very good result. Well Done David |
| awemawson:
Excellent repair. I like the idea of putting a thermo-couple in to monitor the temperature - better than the old trick of rubbing soap on the part and watching it char :clap: |
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