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  #41  
Old 03-25-2018, 05:50 PM
Dave12 Dave12 is offline
 
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Location: Elkton, Md.
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Quote:
Originally Posted by PilotBrent View Post
Add me to the list of broken brackets. Saw it this weekend (420h) but it may have been there in the past and I never noticed it. Credit this post for even knowing where to look. Really don't think I have excessive vibration although I've never had the propeller balanced. Might be an argument to do that.
Never balanced eh?
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  #42  
Old 03-27-2018, 07:43 PM
RFSchaller RFSchaller is offline
 
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Location: Phoenix, AZ
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FYI my prop was dynamically balanced and the little bugger still broke!
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  #43  
Old 04-29-2018, 09:05 AM
PilotBrent PilotBrent is offline
 
Join Date: Dec 2011
Location: Hackettstown, NJ
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Been meaning to post this. I went ahead and fabricated a very basic replacement ignition coil bracket from some scrap aluminum angle I had in the hanger. But, before installing it a friend at the airport dropped by, who has a machine shop and also an amazing basement workshop, and insisted that we fabricate a more durable replacement out of 4140 steel that would be less prone to break again. I shot this short video for our EAA chapter (we're going to visit his basement in a few months). He added a third side to the bracket to strengthen it, but (not in the video) I needed to remove much of that in order to be able to get a small wrench in there to reinstall the bracket on the engine. Those of you have have had to make this repair know how tight it is in there.

Over engineered. YES. But was really interesting to see a skilled machinist in action. After weeks of maintenance in abnormally cold spring weather, several SBs, and this last repair, the annual inspection that wouldn't end is finally done...

P.S. if you check Lockwood's website, the replacement bracket (# 851260) can be purchased for something like $11 (surprisingly cheap compared to most Rotax part prices). So if this one fails, I'm obviously just going to buy the next one.

https://youtu.be/dFLTrf4WRl4

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  #44  
Old 04-29-2018, 05:42 PM
Dave12 Dave12 is offline
 
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Location: Elkton, Md.
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I donít think that one wil break pal! Obviously this is the gent you were telling us about?
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  #45  
Old 04-29-2018, 09:10 PM
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wjb wjb is offline
 
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Great video! I'd love to have access to a shop like that.
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  #46  
Old 04-30-2018, 06:02 AM
Dave12 Dave12 is offline
 
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Quote:
Originally Posted by wjb View Post
Great video! I'd love to have access to a shop like that.
If itís who I think it is, all that great equipment is in his basement. Impressive!
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  #47  
Old 04-30-2018, 09:39 AM
EXflyer EXflyer is offline
 
Join Date: Jan 2016
Location: Chiloquin OR
Posts: 72
Default Bracket

I see a great item taking care of a problem nothing over engineered here just done to fix a problem like Rotax should have done years back. The metal remaining is more than enough to take care of the problem. Well done and hey guys, a small milling machine and a mid sized lathe are in my garage and have been used on many things other than my large scale trains.
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  #48  
Old 05-01-2018, 09:18 PM
RFSchaller RFSchaller is offline
 
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Location: Phoenix, AZ
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My German cousin is a ROTAX mechanic. He got me a couple of replacement brackets, and he said this issue is not common to other aircraft types. Seems weird we are so ďblessedĒ in the RV-12 world.

I took all the dimensions on the ROTAX parts so I can make replacements in the future.
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  #49  
Old 05-02-2018, 01:54 PM
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Piper J3 Piper J3 is offline
 
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Location: Hinckley, Ohio
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It looks like most ignition mounting bracket failures are the stubby 90 degree brackets on the back of the ignition coils. I have not had this failure, but now at my latest oil change (325TT), I noticed the long front bracket has failed just below the 90 degree bend. This is PN 29 in the attached drawing. The bracket is 0.080” Stainless Steel. I have fabricated a new bracket from 1/8” mild steel and added 1/8” to the overall width for additional strength.

Attached photos show broken bracket and 1st iteration of new bracket to test fit. A second more professional bracket is now installed on the engine.
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Jim Stricker
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PPL/ASEL 1970 Sport Pilot since 2004
80 hrs Flying Aeronca Chief 11AC
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RV-12 E-LSA #120058 AWC Jul 2012 - Bought Flying Oct 2015 with 48TT - Hobbs now 366

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  #50  
Old 05-02-2018, 06:33 PM
Dave12 Dave12 is offline
 
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Itís a shame you donít know Brentís buddy.
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