Airplane Owner Maintenance

A Maintenance Oriented Podcast For Airplane Owners, Pilots, and Mechanics

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223 – Piper Cherokee Annual and Other Maintenance Adventures

May 26, 2023 /

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In the beginning of this week’s podcast episode, I want to give a big congratulations to my friend, Chris Wieczorek, who recently got his A&P certificate!

Listen to the audio to find out how Chris pursued getting his A&P in the midst of being a full time attorney and engineer with a wife and 4 kids!

Chris, you are an inspiration! Well done!

This week I also had the opportunity to take care of a couple issues on my friend, Dave Ovad’s Bonanza… you can hear more about these items as well in the podcast:

  1. We turned up his full power fuel flow a bit to bring the CHT’s down.
  2. We installed a couple very specific washers in his nose gear retraction linkage at the idler arm connection. The washer part number is 100951CR016YF.

It’s always good to see Dave!

Now for the Piper Cherokee… this is the one I’m completing an annual inspection on, along with some squawk repairs.

Here’s a list of some items on the Cherokee we discuss in this podcast episode:

  1. Resealing and lubing the fuel selector valve.
  2. Installing a new flash tube in the tail strobe light.
  3. Replacing the old style throttle and mixture control rod ends with the new rod end bearing style rod ends.
  4. Replacing one cowling pin bushing (part number 69790-000.)
  5. Installing a new 28L battery in the ELT remote switch in the instrument panel.

The final two items we talk about in this episode are two different electrical issues on two different airplanes.

The first one is an A36 Bonanza, and the new alternator has been dropping off line. (The alternator was replaced again and then the voltage regulator, at another airport, and that did not fix the problem.)

Through Beechtalk, we discovered a fix for this issue has been developed, where you install a special part number capacitor between the F1 and F2 terminals on the alternator, thus dampening out the voltage spikes that sometimes happen during the break-in phase of a new alternator.

Hopefully this will solve the problem!

The second electrical problem is on a Cessna 210, and it’s one of those weird and frustrating situations that’s hard to figure out. It does fine on the ground, and then in the air, the alternator output circuit breaker is popping intermittently. (Although I need to verify this directly with the owner.)

Hopefully we can solve this one soon as well.

The final phase of this podcast episode is about a couple recent flights in a King Air 200. One of these was to Dulles (KIAD) and how we were routed onto the approach. We usually fly KSHD direct to CSN (Cassanova VOR) and then direct to IAD.

This time, we would be landing on 19C, and we were cleared “After CSN, turn left direct to” (and here’s where I can’t remember the name of the intersection, and it’s driving me crazy!) It was something that sounded like “you-dee-ah” or something like that. Maybe something like “UDIYA” except that’s not it.

If you know what this fix or intersection is called, please let me know… thanks!

Thanks for listening to the podcast, and have a great week!

The post “223 – Piper Cherokee Annual and Other Maintenance Adventures” appeared first at AirplaneOwnerMaintenance.com

222 – How an Engine Cylinder Went From 25/80 to 75/80!

May 13, 2023 /

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I inspected another A36 Bonanza recently, and one of the cylinder compressions was too low… lower than the minimum prescribed by Continental using the master orifice tool.

I had two options:

Option One: Remove the cylinder for repair or replacement.

Option Two: Make the exhaust valve seal better and improve the compression result in hopes of saving the cylinder from premature amputation.

I chose Option Two.

It was at least worth a try…

… and the result was stunning!

After lapping the valve in place and installing a new rotocoil, I ran the engine again and rechecked the compression.

It was 75/80!

The lowest cylinder on the engine was now the highest cylinder.

I also lapped the exhaust valve in cylinder #2, and that one improved from 49/80 to 63/80.

If you’d like more info about valve lapping, click here for episode 109.

Another surprise during the inspection was a cracked / leaking exhaust riser.

Here’s a close-up view of the bad area:

Also in this episode, I talked about some other squawks that were repaired during the inspection. Be sure to listen to the audio for all the details.

In Part Two of this episode, I talked about our most recent trip in the King Air. It was quite an adventure navigating some weather situations!

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221 – Maui Adventures in the Air and on the Ground!

April 21, 2023 /

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Maui is simply amazing!

Maria and I thoroughly enjoyed our trip, and here are some highlights. (And for the aviation maintenance portion of the trip, see the last episode, 220.)

So many indescribably beautiful beaches to see:

Maria and her new friend, Firmiana, at the Upcountry Farmers Market… the most amazing farmer’s market I’ve ever seen!

Maria was right at home with all the fresh fruits and vegetables.

A ridiculously delicious dessert at Kimo’s in Lahaina… Hula Pie. Chocolate cookie thin crust, Macadamia nut ice cream, hot fudge, mac nut pieces, and whipped cream!

Gus’ Shave Ice! It’s the best shave ice on Maui… made with frozen fruit.

Our new friends, Melissa and JT, who we met in line at “The Cinnamon Roll Place” in Kihei.

A super amazing air tour with Leslie and Erica.

A favorite stop on The Road to Hana, Aunty Sandy’s Banana Bread.

Waianapanapa State Park, home of the famous “Black Sand Beach.”

Crazy-good pizza and salad at Hana Farms.

Haleakala, the famous 10,000 foot volcano and crater.

Driving back down the mountain… watching for cows along the road and continuous switch-back turns.

After a most amazing two weeks, it was time to leave our little ohana, our home-away-from-home.

…and after all the wonderful-ness, it was time to say goodbye to John and Leslie and return to the mainland.

Thank you John and Leslie for such a super-awesome time on Maui!

If you ever make a trip to Maui, be sure to check out John and Leslie’s websites… the information they provide is a game-changer for planning a Maui adventure:

The Aloha 360 Podcast with John and Leslie Caubble. These episodes have tons of must-have information for a trip to Maui.

The Road to Hana Audio Guide. Learn about the best stops along the Road to Hana, some of which you would drive right past without a guide like this. (Be sure NOT to miss “Aunty Sandy’s Banana Bread” on the Keanae peninsula!)

The Fly Maui Flight School at Kahalui Airport (OGG.) A scenic tour from the air is an absolutely incredible perspective!

The Ultimate Air Maui indoor trampoline park. This is a local favorite for kids’ birthday parties.

220 – An Epic Working Vacation to Maui!

April 16, 2023 /

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We arrived on Maui the evening of March 27 and were greeted by our friends, John and Leslie Caubble, with a “lei greeting” which is a warm welcome with a beautiful ring of fresh flowers around your neck.

We were there to do several things:

  • Connect with our friends, the Caubbles.
  • Work on the flight school airplanes.
  • Enjoy a wonderful vacation.
  • See amazing sights and taste amazing food!

The trip was truly epic.

In this episode, I focused mainly on the airplane side of things.

In the next episode, I’ll talk about the incredible airplane ride Leslie took us on, and also some of the other adventures we enjoyed.

So here we go… the morning after we arrived, Leslie gave me a tour of the airport and turned me loose to begin a 100 hour inspection on one of the flight school Cessna 172’s.

I unpacked my tools and supplies and “set up shop” in the T-hangar.

The first few days, I was overwhelmed and I was having a blast, all at the same time!

Getting used to a new situation, inspecting the airplane, and fixing the things that needed fixing were all worthwhile challenges, and I’m super thankful for the opportunity.

And, it turned out that all three of the school’s airplanes came due for 100 hour inspection within about the same week. I did one of the inspections, and helped with the other two.

What an adventure!

Occasionally, I’d take some time to go enjoy a local beach with my wife Maria before going to the airport… there are so many great beaches to choose from!

We packed so much into our short 2 weeks on Maui, and I’ll share some of those adventures in the next episode.

The day before we left was Easter Sunday, and we were so blessed by the 7 am service with John and Leslie at Hope Chapel in Kihei.

Mahalo Nui Loa (thank you very much) to John and Leslie for an absolutely amazing time on Maui!

… and more to come in the next episode!

P.S. If you ever get the opportunity to visit Maui, it’s totally worth it! I highly recommend the following resources that will make your trip so much better:

The Aloha 360 Podcast with John and Leslie Caubble. These episodes have tons of must-have information for a trip to Maui.

The Road to Hana Audio Guide. Learn about the best stops along the Road to Hana, some of which you would drive right past without a guide like this. (Be sure NOT to miss “Aunty Sandy’s Banana Bread” on the Keanae peninsula!)

The Fly Maui Flight School at Kahalui Airport (OGG.) A scenic tour from the air is an absolutely incredible perspective!

219 – I Installed New Brake Linings and the Wheel Would Not Turn!

March 23, 2023 /

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It took some significant detective work and deciphering to solve this mystery.

The brake caliper at the top of the photo was the wrong part number for the A36 Bonanza I was working on.

The one at the bottom of the photo is a serviceable one we found on eBay. It was the correct one, and the 1/8 inch extra depth at the edges of the caliper made all the difference.

This problem apparently went unnoticed for an undetermined amount of time.

The only reason I discovered the problem was because I installed new brake linings and after reassembling the brake caliper, the wheel would not turn at all. Everything seemed to be working fine with the worn linings.

But new linings made it too tight for the wheel to turn.

After installing the correct brake caliper, everything was back to normal.

What an ordeal! I’m glad it’s fixed.

In this week’s podcast episode, I talked about the brake situation above, and about some flying from this week.

Here’s a sampling of the places I had the opportunity to fly to this past week:

  • Near Myrtle Beach SC.
  • Pennsylvania
  • New York
  • Montpelier VT
  • Chattanooga TN
  • Dalton GA

And just for fun, here’s a photo of the King Air on the ramp in Vermont… we put the engine and pitot covers on for the night while we were there.

Thanks for checking out the podcast! The next episode might just come from Maui! We’ll see.

The post “219 – I Installed New Brake Lingings and the Wheel Would Not Turn!” appeared first at AirplaneOwnerMaintenance.

218 – Engine Oil was Seeping Out of the Top Cowling

March 17, 2023 /

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Not long ago, there was an oil leak on the right engine of a Cessna 414. The leak was significant enough to come out the louvers on the top cowling in flight. There was oil all over the rear inboard area of the engine, so the big question was, “Where is the oil leak coming from,” or “Where is the source?”

With so many possibilities, it was difficult to find the leak.

After multiple cleanings and ground runs, it was becoming more clear.

It was still however, hard to be certain. It seemed to be coming from the inboard forward base of the oil cooler. A flashlight and small mirror were somewhat helpful to see the area:

The borescope was also helpful to take a closer look:

Finally, after making the best evaluation I could without disassembling anything, I told the owner I was fairly certain the oil cooler was leaking… it seemed there might be a small crack in the oil cooler.

The annual inspection was already scheduled for this airplane, so it made a good time to verify the oil leak. The owner is an A&P, and he removed the oil cooler himself. I was hoping I had not steered him down the wrong path on this one!

He discovered it’s not an easy task to remove the oil cooler from his engine, but he persisted and got it done.

He sent me a text message and told me he had removed the oil cooler and when they first looked at it, he was not sure it was cracked. But after pressurizing it with 5 pounds of air pressure, the leak was obvious.

About the oil cooler, he told me “I tell you it was a job getting that off.”

The black circled area is where the crack was:

And here’s the really fun part… watch this video to see the bubbles confirming the source of the oil leak:

Here’s the engine after the oil cooler was removed… definitely “major surgery!”

This was the main maintenance topic in this week’s podcast, and we also talked about these items as well:

  • Aerostar voltage regulator adjustment.
  • Alternator charging system troubleshooting.
  • Our upcoming trip to Maui!

Thanks for listening, and we’ll see you in the next episode!

The post “218 – Engine Oil was Seeping Out of the Top Cowling” appeared first at AirplaneOwnerMaintenance.com

217 – Does Your Magneto Have Any Broken Teeth?

March 10, 2023 /

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I recently removed a magneto from a Piper Cherokee, and my curiosity about why the magneto had failed got the best of me.

I took the mag home, sat down at the kitchen table, put my grandson Spencer on my lap, and took the magneto apart! It was great fun having him help me 🙂

Before long, we had the case apart, and it quickly became obvious why the magneto wasn’t working… there were 6 broken teeth on the distributor gear! And 3 of the broken teeth were together in a row, making it impossible for the distributor gear to mesh with the drive gear… this mag was completely dead.

It had been more than 600 hours since the last 500 hour magneto inspection.

I wonder how long it had been since the first tooth broke… we’ll never know.

But it does remind me of the importance of doing 500 hour magneto inspections. For Part 91 airplanes, it’s a recommendation and not a requirement, but in this case, I think the recommendation is a really good one.

You can listen to the podcast episode for more details about the troubleshooting process on the magneto, and here are some other items also included in this episode:

  • Some King Air flying this week (I never get tired of the “view from the office!”)
  • Our complex ATC clearances we received on the way to the Boston area.
  • The annual inspection I’m currently doing on an A36 Bonanza… here’s the overhauled alternator drive coupling I installed because the old one failed the slippage torqe test:
  • Our IA renewal seminar at Blue Ridge Community College… it’s always a good time to see friends, learn some things, and satisfy the FAA requirements to keep my IA certificate current.
  • And finally, Maria and I are getting very excited about our trip to Hawaii! We’re going to visit John and Leslie Caubble on Maui, and I’ll be working with them on the flight school airplanes at FlyMauiHI.com It’s going to be a grand adventure!

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216 – WHY is the alternator not working?!

March 3, 2023 /

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Here’s the short answer: Worn and contaminated brushes inside the alternator. Check it out:

My theory is that the excessive amount of carbon dust from brush wear was causing a short circuit situation between the brushes, and not allowing the field circuit in the alternator rotor to be properly energized for normal operation.

Here’s a comparison of the old and new brushes:

This story comes from a recent situation on the right engine of this Aerostar aircraft:

Since the alternator has externally removable brushes, it turned out to be a minimally invasive surgery to fix the problem. I cleaned the brush holder and also the slip rings inside the alternator, and after installing new brushes and reassembling everything, the alternator performed flawlessly.

Listen to the audio to hear the full story.

This episode also covers some of the email responses I received last week from some listeners, and here’s one of the highlights:

Glen sent me a photo of he and his dad in front of his Piper Cherokee… I love to see different generations enjoying aviation adventures together!

One more fun fact: Glen’s mom took her private pilot check ride years ago with Glen in the back seat of their Cessna 175 when he was 3 weeks old! What a great story!

Thanks Glen, for sharing some of your story with us!

This episode also covers a recent trip to Charlotte in another Aerostar, and the interesting routing we got from ATC on the way there… definitely some great IFR and ATC lessons to observe and learn from this one!

The Charlotte trip also sparked some conversation about twin engine charging systems, and paralleling issues that can happen… this situation is still in process, and I’ll try to give an update sometime in the future.

Finally, I had the privilege of joining Carl Valeri, Tom Frick, and Bill English on episode 301 “What is Your Most Challenging Approach” of the Stuck Mic AvCast. It was great fun talking about challenging approaches, both instrument and visual approaches.

Here’s a link where you can listen:

SMAC301 What Is Your Most Challenging Approach?

I also highly encourage you to check out Carl Valeri’s Aviation Careers Podcast:

http://www.aviationcareerspodcast.com/

You can also find the Aviation Careers Podcast on YouTube.

https://www.youtube.com/@AviationCareersPodcast

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215 – Vacuum Pump Adventure with Clark, my Airline Captain Friend

February 24, 2023 /

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Clark and his family came to Virginia to visit his mom recently, and on the way up from Florida, the right vacuum pump quit working… as often happens when a vacuum pump quits, the drive shaft had sheared off, saving the engine from catastrophic damage.

In times like these, a good question to ask is, “What does this make possible?”

In this case, it made it possible to tackle a maintenance project with a good friend!

You can listen to the audio in this week’s podcast to hear about how I got to know Clark, and how he became the kind of friend I would want to go the extra mile for, whenever I can.

We changed the broken vacuum pump, installed new filters, and got him all set for the trip back home. (Ask him if he got to fly much on the trip… the answer would be no, because his wife is learning to fly and she took over the controls for most of the trip 🙂

It’s always fun when you can get an airline captain turning wrenches! Clark is very mechanically inclined, and I think the whole experience put a big smile on his face.

Another highlight recently on a Saturday morning was when I took my mom for an airplane ride… she’s 86 years old and still very happy to get in a little airplane and go flying! We had a great time flying around the beautiful Shenandoah Valley. You’ll hear about this story in this episode as well.

And finally, my wife Maria and I have an exciting trip planned in just over a month from now… we’re going to Hawaii for the first time! Our friends, John and Leslie Caubble, operate a flight school on Maui, so we’re going to visit them and I get to help work on the flight school airplanes… we’re super excited about this adventure!

You can learn A LOT more about John and Leslie through their two podcasts, The Aloha 360, and Fly Maui. They are simply GREAT people!

https://www.flymauihi.com/blog

https://www.thealoha360.com/podcast

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214 – An Unacceptably Low Cylinder Compression

February 17, 2023 /

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This is a good looking exhaust valve with a nice concentric appearance. However, the compression was very low at 8/80.

I lapped the valve, hoping it would improve the compression test result… it only came up to 10/80, and that was after running the engine again and getting it nice and hot.

Although the valve face showed a healthy appearance, the seating area was telling a different story. Check out the following borescope photo of the seating area showing a possible leaking area:

It appeared there was abnormal wear on the valve seat, and the valve was not able to seal well, causing an unacceptably low compression result.

Listen to the audio for more details on this one.

I asked the question, “Borescope or compression tester… which one is better?”

Let me know what you think after listening. I’m curious to hear your thoughts.

Just click the button over to the right and record a brief audio message for me.

Thanks!

We ended up sending cylinder #5 out for repair, and then reinstalling it.

We did a test flight today, and everything went very well… ready to go for another year!

Here are some links to information on cylinder / engine break-in procedures:

Lycoming SI1427C

Proper Engine Break-In
Engine Break-In: It’s Easier Than You Think

Savvy Aviation / EAA webinar slides by Mike Busch (Cylinder Break-In.)

Let me know if you find other excellent resources on this topic.

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