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  #551  
Old 06-12-2018, 07:18 PM
Steve Melton's Avatar
Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
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looks good but doesn't work. a flat spot on the inboard and outboard edge created by the riveted cap flange prevents a good seal. further from the cap, between the ribs, the fit is good but don't need it there. need to adjust the surface profile and change to a more compliant gasket. overall, I still like the concept.




edit: this is DIY paint (no buffing), sometimes you just have to smile



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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com

Last edited by Steve Melton : 06-13-2018 at 04:55 AM.
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  #552  
Old 06-15-2018, 01:14 PM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
Posts: 1,741
Default proto3 fuel cap cover

added contour adjustment features to the model. changed to a more compliant seal.





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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com

Last edited by Steve Melton : 06-16-2018 at 05:58 AM.
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  #553  
Old 06-16-2018, 07:32 AM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
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will also evaluate this soft seal.



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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com
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  #554  
Old 06-16-2018, 08:11 PM
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Steve Melton Steve Melton is offline
 
Join Date: Apr 2011
Location: Cincinnati, OH
Posts: 1,741
Default fuel vent cover - slip on

reduced to two blades





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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com
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  #555  
Old 06-17-2018, 07:58 AM
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Steve Melton Steve Melton is offline
 
Join Date: Apr 2011
Location: Cincinnati, OH
Posts: 1,741
Default RV10 PC680 battery tray

kicking around a PC680 battery tray

the floor of this tray is raised .020 to ensure no contact on the radius edges.










a nice print

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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com

Last edited by Steve Melton : 06-17-2018 at 04:22 PM.
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  #556  
Old 06-17-2018, 04:30 PM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
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Default fuel cap cover - water and wind speed test

water test was good. wind speed test, fuel cap cover departed at 35 kts on the runway. I am using grade 50 magnets but the fuel cap stem is stainless so not much mag force, but enough to make a good seal. need to find a way to withstand at least 70 kts. I have an idea how to do this.




fuel cap is dry



on route to high speed taxi

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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com

Last edited by Steve Melton : 06-18-2018 at 05:21 AM.
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  #557  
Old 06-18-2018, 04:16 PM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
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Default fuel cap cover magnet with hook

the RV9 prototype fuel cap cover with magnet only departed the wing at 35 kts on the takeoff roll. the vibration from the takeoff roll could have contributed to the separation. so perhaps it could stay attached at a higher speed if vibration was not present. it's a slim clean design that only weights 21 grams.

the next prototype will include a hook that slips in the space just fwd of the latch. perhaps with both the magnet and hook I can reach the goal of 70 kts.

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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com
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  #558  
Old 06-18-2018, 08:46 PM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
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Default RV9 fuel cap cover

further testing is promising. I found that orienting the gap in the seal to the side adds 10 kts to the separation speed for the non-hook variation. that's another 10 kts delta for separation at 45 kts. it is becoming my favorite because is it so simple and easily stored in the baggage area. the hook version separated at 48 kts but the hook was not optimized. will repeat the test with an optimized hook to achieve the goal of 70 kts. In a weird way I like calling the FBO and notifying that I lost a couple airplane parts on the runway and then scooting by on my Honda CB125 to retrieve them from the runway with the corporate pilots standing in the FBO, looking and shaking their heads.


the blow down test


gap in seal oriented fwd contributed to separation at 35 kts. notch is fwd.



gap in seal oriented to the side added 10 kts to separation (45 kts)



gap with hook with seal oriented to the side separated at 48 kts. the hook was not optimized so this can be better. I'm impressed with the ease of fitting the hook fuel cap cover. I am confident I can reach 70 kts.


a possible storage location. tape on magnet is temporary since I am prototyping.



the test vehicle
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Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com

Last edited by Steve Melton : 06-18-2018 at 09:12 PM.
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  #559  
Old 06-19-2018, 08:10 AM
David Paule David Paule is offline
 
Join Date: Dec 2009
Location: Boulder, CO
Posts: 3,523
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For the folks who have an ADAHRS or magnetometer in the middle of the tailcone somewhere, will this affect their compass calibration?

I'd be concerned that if there was any effect, it would vary day to day as pilots moved these things around the aircraft for storage. In my opinion, magnets in an airplane that aren't permanently fixed in place, might become an unexpected hazard.

Could the magnets be attached to the fuel cap rather than the cover?

Dave
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  #560  
Old 06-19-2018, 10:12 AM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
Posts: 1,741
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Quote:
Originally Posted by David Paule View Post
For the folks who have an ADAHRS or magnetometer in the middle of the tailcone somewhere, will this affect their compass calibration?

I'd be concerned that if there was any effect, it would vary day to day as pilots moved these things around the aircraft for storage. In my opinion, magnets in an airplane that aren't permanently fixed in place, might become an unexpected hazard.

Could the magnets be attached to the fuel cap rather than the cover?

Dave
At this time, I don't know how I could do that. Maybe something will turn up.

My magnetometer is under the aft fairing about six feet away. So it should be OK. My whiskey compass is about four feet forward. It could be affected.
__________________
Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 600+ for all

Simplicity is the art in design.

see Amanda Melton for www.rvplasticparts.com
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