Unexpected Problem! Rebuilding the Air Box on my Cozy MKIV Airplane

Рет қаралды 1,255

Күн бұрын

While removing the air box (an aluminum and fiberglass box that holds the engine air filter) in order to gain access to the SCAT tubing, I discovered some problems: a crack, and wear causing a hole in the fiberglass. Time to pull it off and rebuild it - doing both some fiberglass work as well as aluminum metal work.
0:00 Intro
0:16 Removing the Air Box
0:47 The Problems I Found
3:11 Degreased and Inspecting
5:03 Stripped and Abraded
6:22 Drilling Out Rivets
6:52 Prep and Layup
7:27 Sanding, Prep and Layup
8:14 Trimming, Sanding
8:38 Aluminum Reinforcement
9:18 Sanding, Drilling
9:47 Painting
9:58 Finished Bin, What's Next
11:22 Repair Rivets
11:38 Deburring
11:54 Patching Crack
12:31 Filter Position Tabs
12:51 Riveting Halves Together
13:02 Assembled
No content in this video should be taken as flight instruction or advice. Refer to your aircraft POH and consult your CFI. This video has been edited for time and content, and context may be lost or distorted. This video is for entertainment purposes only.
#Canard #Cozy #AirBox

Пікірлер: 31

@diegoandresbustamante2742 2 ай бұрын

Nice work! loose air filter can really destroys engine TBO and oil consumption. Your channel is an inspiration for me and my canard project.

@jeffwidmann2957 2 ай бұрын

Hey Scott!!! Still LOVE your videos. Especially the maintenance ones! I get excited when you post a new one! Keep up the good work! -Jeff

@TRabbit1970 2 ай бұрын

It’s amazing how quickly the ounces add up!

@TF242 2 ай бұрын

Nice update as usual. Loving the attention to detail!

@vernebrown4441 2 ай бұрын

Hi Scott Was thinking why not put some tabs on the bottom plate to keep it in place. Then see you were thinking of that just from the top, way to go ;-)

@valleyken 2 ай бұрын

- Wow, that was some advanced repair work. I would have thought that it needed to be thrown out and bought a new one. But it looked pretty good after you fixed it up 😀

@CanardBoulevard 2 ай бұрын

When you consider that a new one costs $700 (and would still need to be modified to fit my plane - and would still have the same wear problem), there is considerable motivation just to fix what you have on hand. :)

@carlbeaver7112 2 ай бұрын

Nice job, looks good. I was thinking, while watching, that a deflector, in front of where the in-rush of air hits the filter, would probably prevent the high flow of air in that one area from opening the pores of the filter media. Just a vee shaped piece between the base and the cover, where the neck opens in front of the filter, would be adequate.

@CanardBoulevard 2 ай бұрын

It's actually more complex than that. There's a reason for the shape - it's called a pressure recovery box. It has a relatively small opening where the high velocity air enters. Air pressure drops as velocity increases, so this high velocity air has low pressure. The throat of the airbox opens up immediately after the entry, which instantly slows the air down. As the velocity slows, the pressure increases - the net result is that there isn't a "blast" of air directly on the filter, but instead a high pressure surrounding the filter, acting almost like a miniature supercharger to raise manifold pressure and give you a little extra power.

@johugra1 2 ай бұрын

I know nothing about this but found the video was well edited. By that I mean it went at just the right speed to be clear, concise and interesting.

@valleyken 2 ай бұрын

I know nothing about airplanes or mechanics either. But Scott has indeed a talent to explain things in a clear way and keep it interesting. I came here from his synth channel, but now I really like this airplane channel a lot also.

@BrianRhodes9763 2 ай бұрын

Great video Scott, by the way those lug fasteners are called nutplates probably MS21048 or MS21069 depending on the spacing of the rivets.

@CanardBoulevard 2 ай бұрын

That's right. I actually have both on hand, don't recall which these were, but I had a replacement to use!

@larrynoe6162 2 ай бұрын

Nice work Scott, no corners cut. Love your show, let’s go back to Sweetwater. Ready to see you flying again.

@CanardBoulevard 2 ай бұрын

I'm SO close! Maybe a week away from flying again

@Ronzola1 2 ай бұрын

I’m wondering, since you put aluminum on the bottom of the box, why didn’t you bend a lip around it to capture the filter to retain its shape and not restrict air flow like the tabs you installed around the top?

@CanardBoulevard 2 ай бұрын

I like your idea! It would have required some way of scribing a ridge around the circular plate - not easy (at least not without metalworking tools), but it definitely would work if you could do it.

@flysport_tedder 2 ай бұрын

8:12 I'm very curious about the "curing tent" thing. Do you add heat? Does it contain the fumes a little bit? Keep flies from landing on it?

@CanardBoulevard 2 ай бұрын

It is a heated plate with an insulated hood, and holds a specific temperature for a given amount of time. It drastically accelerates the curing time (full cure in around 3 hours rather than 24), but more importantly, the cured epoxy has increased strength, elevated glass transition temperature and reduced residual stress. The glass transition temperature is the temperature at which the cured epoxy goes from being rigid to more flexible. The temperature and times vary for different epoxies, so you need to do some research first.

@flysport_tedder 2 ай бұрын

@@CanardBoulevard aha. thanks for the big reply. it sounds somewhat like tempering glass or steel, really managing the temperature changes.

@johntoncinich1176 2 ай бұрын

For the bottom part, and maybe i have not got to this part yet, but did you consider making a mold, and refabricate?

@CanardBoulevard 2 ай бұрын

No need to, this is easily rebuildable. I suppose I could have made a mold to manufacture more of them, and perhaps I should have - as Van's sells those FAB's for $700 apiece!!

@vernebrown4441 2 ай бұрын

Wow That a lot of coin....airplane add $$$$ when it 's only cost 1/2 of a $ to make.

@jimmyupson1959 2 ай бұрын

How does the filter move if it's seated to the carb?

@CanardBoulevard 2 ай бұрын

It's pushed up between the bottom of the throttle body plate and the bottom of the air box. The only thing holding it in place is friction, and lots of oil gets down in there, reducing that friction - so with engine vibrations (plus the filter physically shrinking in size), it starts moving all over the place. That won't happen anymore.

@berniebrown9115 2 ай бұрын

Scott I am impressed with your meticulous attention to detail, but you would not make a good farmer. Believe me I know what makes a good farmer because I come from a long line of farmers. You can’t be a good farmer without at least three hammers. In fact my dad’s most important advise to me was if it won’t work get a bigger hammer!

@CanardBoulevard 2 ай бұрын

I have several hammers! :) Just not at the airport