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  #1  
Old 10-10-2015, 02:57 PM
WingedFrog's Avatar
WingedFrog WingedFrog is offline
 
Join Date: Mar 2010
Location: Raleigh, NC
Posts: 856
Default Check this at your next annual

During my annual inspection I caught a broken bracket under the ignition module. I caught it by chance just because the vibration had created a polished crack that reflected my torch light. Very tight place, no easy access for repair and after finding how this bracket was made originally by Rotax (by bending 90 deg a pretty thick piece of Al), I decided to fabricate one (out of an Al angle) that should be less likely to crack. I suspect that I missed this broken bracket at my last annual because it was not polished enough...

Here is the faulty bracket with the new one I fabricated:



Here is the location where the bracket can be inspected (the new bracket shown here after repair):


You can easily understand why this cracked bracket might be difficult to detect (although I found afterward that pulling the ignition module up will show the crack once the bracket is broken)
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  #2  
Old 10-10-2015, 03:15 PM
Mike H Mike H is offline
 
Join Date: May 2014
Location: Savannah
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You really shouldn't use a torch within 50 feet of flammable liquids such as gasoline...just sayin.
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  #3  
Old 10-10-2015, 03:44 PM
DHeal DHeal is offline
 
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Location: Windsor, California
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I believe Jean-Pierre is from either Canada or France - a "torch" is a flashlight to them.
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  #4  
Old 10-10-2015, 04:13 PM
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WingedFrog WingedFrog is offline
 
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Location: Raleigh, NC
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Default

Quote:
Originally Posted by Mike H View Post
You really shouldn't use a torch within 50 feet of flammable liquids such as gasoline...just sayin.
Excuse my French! (In French, torche is a flashlight).
Still, that was funny!
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Builder's name: Jean-Pierre Bernoux
Sport Pilot
Kit # 120395 N124BX
Flying as of 9/11/2013

Builder's Blog:http://vieilleburette.blogspot.com/
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  #5  
Old 10-10-2015, 05:25 PM
Mike H Mike H is offline
 
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Location: Savannah
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I know what he meant...just joking. Glad you found the cracked bracket. That new bracket should do the trick.
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  #6  
Old 10-11-2015, 04:28 AM
Hotscam Hotscam is offline
 
Join Date: Mar 2011
Location: Bosschenhoofd, Netherlands
Posts: 138
Default

On my 12 the same bracket broke at about 400 h.
**** of a job to fit a new one.
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  #7  
Old 10-11-2015, 06:44 AM
n233va n233va is offline
 
Join Date: Jul 2014
Location: Prescott, AZ
Posts: 20
Default Same Broken Bracket

I also had the same broken bracket on the ignition module at 325 hrs.
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  #8  
Old 10-11-2015, 07:54 AM
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WingedFrog WingedFrog is offline
 
Join Date: Mar 2010
Location: Raleigh, NC
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Jack and Bob: are you sure about the number of hours when your bracket failed? As I mentioned, the failure may go unnoticed as there is little consequences to it. Indeed the ignition stack is set on the top of 3 "silent blocks" (an other French term?) of generous dimensions regarding the mass they support. Only one of these rubber dampers is using this type of bracket, the two others have a sturdier attachment. What I don't understand is why Rotax, with all it's mechanical wherewithal, is using a bent piece of thick aluminum for a bracket.
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Builder's name: Jean-Pierre Bernoux
Sport Pilot
Kit # 120395 N124BX
Flying as of 9/11/2013

Builder's Blog:http://vieilleburette.blogspot.com/
EAA 1114
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  #9  
Old 10-11-2015, 08:16 AM
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curtis curtis is offline
 
Join Date: Jan 2005
Location: Kansas
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Default

I see two possible issues with your new bracket;
1 - It looks like it is not the structural Al angle, no radius in the inside corner
2 - There appears to be a notch in the inside corner of the new angle, which may be a new failure point.

My questions are only based upon the image and may not be accurate.
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  #10  
Old 10-11-2015, 10:19 AM
rockwoodrv9 rockwoodrv9 is offline
 
Join Date: Dec 2011
Location: Meridian ID, Aspen CO
Posts: 2,383
Default

My question, is an aluminum angle as strong as bent aluminum? Maybe it is stronger? I do agree the angle in the picture does not look like structural angle.


Quote:
Originally Posted by curtis View Post
I see two possible issues with your new bracket;
1 - It looks like it is not the structural Al angle, no radius in the inside corner
2 - There appears to be a notch in the inside corner of the new angle, which may be a new failure point.

My questions are only based upon the image and may not be accurate.
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