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912 Throttle Cable Failure
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Dennis.Kirby(at)kirtland.
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PostPosted: Thu Apr 19, 2007 10:55 am    Post subject: 912 Throttle Cable Failure Reply with quote

Kolb Friends -

This morning, when flying my Mark-III, I experienced a broken throttle
cable on the 912ul engine. This awarded me the opportunity to execute
my FIRST dead stick landing in my Kolb. I'm happy to report the landing
was uneventful.

I had been flying for about 15 minutes; I was about 3 miles from my home
field. I wanted to look at something in a field, so I descended and
retarded the throttle to get a bit closer. At about 100 feet AGL I felt
a snap in the throttle lever and the mighty 912 went to full throttle.

I knew exactly what had happened: the throttle cable had broken
somewhere, and the 912 series engines are designed to go to full
throttle if this happens. Flew back to my airport, entered the pattern
(still at 100%), established a downwind at 1000 AGL, then flipped the
magneto switches to "off."

What a rush.

All your senses are screaming at you in alarm, in the very unfamiliar
silence. I pegged my glide rate at 55 mph, and the airplane felt very
stable. What I also realized was, this Mark-III was descending more
steeply than my usual power-off (idle) approach. Obviously, the stopped
prop creates more drag than an idling engine, for my setup anyway. I
used half flaps for landing, but would have been better off if I had
used none.

I announced to the traffic pattern my situation - that I was dead stick
and headed for THAT runway. (I even got to say "mayday" on the radio.)

After landing, I had to push my 650 lbs of airplane a half mile back to
the hangar. (Whew - good workout!) But WAY better'n being stuck out
somewhere, if I had been forced to land because of carburetors that
spring to idle.

I disassembled the throttle splitter tube and confirmed that the cable
had indeed separated from the splitter assembly. The tiny brass ferrule
that is soldered to the end of the cable (this is what keeps it seated
in the splitter slider) had pulled off. I had soldered this ferrule on
during construction. It was my own workmanship that failed here,
nothing the fault of the Rotax.

After discussing the details with the local A&P at my airport, he
concluded that is was likely a cold solder that caused it to let loose.
His advice was to get a hotter soldering iron (or flame), tin the
braided strands well before flowing the solder in. Even if you are
using solder with flux in it, still apply flux to the braided cable
before you touch it with the solder.

It is fascinating to me how the mechanical failure of a part the size of
an uncooked grain of rice can put you on the ground.

And the 912ul fail-safe design of the carb setup got me home safe. I
love this little engine.

Lesson here is: Give appropriate attention to even the LITTLE details
during your building process. That tiny little brass ferrule needs to
be soldered correctly for it to do it's job.

Dennis Kirby
Mark-III, 912ul, 66.6 hrs on the Hobbs when I took off, this flight, in
Cedar Crest, NM


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Ralph B



Joined: 14 Apr 2007
Posts: 367
Location: Mound Minnesota

PostPosted: Thu Apr 19, 2007 11:18 am    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Dennis, I'm happy to hear that everything turned out fine and that you landed that bird without incident.

Ralph


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Kolb Kolbra 912uls
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Paul Petty



Joined: 11 Jan 2006
Posts: 226
Location: Mississippi

PostPosted: Thu Apr 19, 2007 11:25 am    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Dennis,

Excellant job sir! I strongly agree, WOT in failure gives you alot more options no doubt. Lets say I took off from our 1700' (tight) strip and that happened in the pattern. With fuel, I could go find a 5000' runway to land her.

glad your ok and can add dead stick to your log book!
do not archive


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Kolbra #12
Ms Dixie
912 UL 70" warp
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lcottrell



Joined: 29 May 2006
Posts: 1494
Location: Jordan Valley, Or

PostPosted: Thu Apr 19, 2007 11:33 am    Post subject: 912 Throttle Cable Failure Reply with quote

[quote]
<Dennis.Kirby(at)kirtland.af.mil>


Kolb Friends -

This morning, when flying my Mark-III, I experienced a broken throttle
cable on the 912ul engine. This awarded me the opportunity to execute
my FIRST dead stick landing in my Kolb. I'm happy to report the landing
was uneventful.


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Paul Petty



Joined: 11 Jan 2006
Posts: 226
Location: Mississippi

PostPosted: Thu Apr 19, 2007 11:41 am    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Dennis,

That post was so exciting I had to read it again!

"Flew back to my airport, entered the pattern
(still at 100%), established a downwind at 1000 AGL, then flipped the
magneto switches to "off."
Just curious, did you turn L/R base then L/R final with no power?

If so then that would explain the "What a rush" LOL

I know alot of things go through ones mind and Im by no means saying what I would have done. But monday morning quarter backing I would have called the "mayday" or anounced my situation to the ground and or traffic and went WAY out and called "straight in" everybody get the hell out of my way!

If you chopped the power as you beaked the numbers how well did she glide in the 180?

do not archive


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912 UL 70" warp
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Roger Lee



Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

PostPosted: Thu Apr 19, 2007 12:06 pm    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Hi Dennis,

Glad everything went ok after the break.
This is why I think everyone should go up and turn the engine off while in control and practice dead sticks. They are really easy as you now know first hand. It gves you new confidence that if something happens it's really not a high stress issue, but only a landing one.

All cable ends that get pulled on or have stress should be a hot solder, but a word of caution, do not over heat or apply too much heat too long. It will cause your cable to become brittle. Just enough heat to cause the flux to flow and the solder to flow and then remove the heat. One time when I was doing a hot solder on a cable I did not like my solder joint at the cable end. I applied heat too long. When I went to check on the cable strength and flexibilty it snapped just behind the new solder. Too much heat, i.e. from a torch, will cause a cable failure. You can use the torch, but no more heat than necessary to melt the solder.


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Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
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by0ung(at)brigham.net
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PostPosted: Thu Apr 19, 2007 12:37 pm    Post subject: 912 Throttle Cable Failure Reply with quote

Quote:
>>>>>>>> I pegged my glide rate at 55 mph, and the airplane felt very
stable.>>>>>>>>>>>>

if solo I think you did well..... with 2 on board,,, keep it in the 65 to
70 range.... ask me how I know.....

better yet,,, take up a passenger,,,, while at 65 to 70, pull the
throttle to idle, adjust your glide to maintain your speed, then very
slowly adjust your glide to slow your speed... you will find a speed where
you start to feel that you don't have enough elevator authority.... if you
ever have to dead stick with a passenger,,,,, stay well above that speed.

Boyd


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biglar



Joined: 14 Jan 2006
Posts: 457

PostPosted: Thu Apr 19, 2007 2:11 pm    Post subject: 912 Throttle Cable Failure Reply with quote

Good on you, Dennis. It sounds like you handled it real well. � I've done a lot of soldering and silver soldering in the course of my work, and I've seen both cold solder joints, and overheated connections, as was mentioned in another post. Many times now, or even most times, I'll tin each component separately and very carefully, then put them in position and heat them lightly. Make sure you use the correct flux - some can cause corrosion. When the solder flows, it melts together, and you're done - get the heat off it. The advantage to this, especially with different sized components to be soldered, it makes sure both are properly tinned, whereas if you put them together and solder them, quite often the larger component doesn't receive enuf heat and you'll have a cold solder joint. If it does get enuf heat, quite often that will overheat the smaller and burn the flux....then nothing will stick and you'll have an awful time cleaning it up again for another try. Again, as was said, too much heat is as bad as not enuf. � � Lar.

On 4/19/07, Kirby Dennis Contr MDA/AL <Dennis.Kirby(at)kirtland.af.mil (Dennis.Kirby(at)kirtland.af.mil)> wrote: [quote]--> Kolb-List message posted by: "Kirby Dennis Contr MDA/AL" < Dennis.Kirby(at)kirtland.af.mil (Dennis.Kirby(at)kirtland.af.mil)>


Kolb Friends -

This morning, when flying my Mark-III, I experienced a broken throttle
cable on the 912ul engine. This awarded me the opportunity to execute
my FIRST dead stick landing in my Kolb. I'm happy to report the landing
was uneventful.

I had been flying for about 15 minutes; I was about 3 miles from my home
field. I wanted to look at something in a field, so I descended and
retarded the throttle to get a bit closer. At about 100 feet AGL I felt
a snap in the throttle lever and the mighty 912 went to full throttle.

I knew exactly what had happened: the throttle cable had broken
somewhere, and the 912 series engines are designed to go to full
throttle if this happens. Flew back to my airport, entered the pattern
(still at 100%), established a downwind at 1000 AGL, then flipped the
magneto switches to "off."

What a rush.

All your senses are screaming at you in alarm, in the very unfamiliar
silence. I pegged my glide rate at 55 mph, and the airplane felt very
stable. What I also realized was, this Mark-III was descending more
steeply than my usual power-off (idle) approach. Obviously, the stopped
prop creates more drag than an idling engine, for my setup anyway. I
used half flaps for landing, but would have been better off if I had
used none.

I announced to the traffic pattern my situation - that I was dead stick
and headed for THAT runway. (I even got to say "mayday" on the radio.)

After landing, I had to push my 650 lbs of airplane a half mile back to
the hangar. (Whew - good workout!) But WAY better'n being stuck out
somewhere, if I had been forced to land because of carburetors that
spring to idle.

I disassembled the throttle splitter tube and confirmed that the cable
had indeed separated from the splitter assembly. The tiny brass ferrule
that is soldered to the end of the cable (this is what keeps it seated
in the splitter slider) had pulled off. I had soldered this ferrule on
during construction. It was my own workmanship that failed here,
nothing the fault of the Rotax.

After discussing the details with the local A&P at my airport, he
concluded that is was likely a cold solder that caused it to let loose.
His advice was to get a hotter soldering iron (or flame), tin the
braided strands well before flowing the solder in. Even if you are
using solder with flux in it, still apply flux to the braided cable
before you touch it with the solder.

It is fascinating to me how the mechanical failure of a part the size of
an uncooked grain of rice can put you on the ground.

And the 912ul fail-safe design of the carb setup got me home safe. I
love this little engine.

Lesson here is: Give appropriate attention to even the LITTLE details
during your building process. That tiny little brass ferrule needs to
be soldered correctly for it to do it's job.

Dennis Kirby
Mark-III, 912ul, 66.6 hrs on the Hobbs when I took off, this flight, inKolb-List Email Forum - h more: sp; - NEW MATRONICS WEB FORUMS - = --> http://forum===================

[b]


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Eugene Zimmerman



Joined: 10 Jan 2006
Posts: 392

PostPosted: Thu Apr 19, 2007 5:16 pm    Post subject: 912 Throttle Cable Failure Reply with quote

I personally would never use a torch to solder a cable. Too risky. It
doesn't take much flame to compromise a cable.
I use a small solder pot I made out of a half inch nut with the one
end welded shut. Heat the nut with torch and fill half full of
solder, flux the cable end and ferrule. Dip ferrule half way into the
molten solder and watch for solder to seep up into the cable strands
above the ferrule, remove and let cool.
Never had one come loose ,,,,,,,, yet.

Gene

On Apr 19, 2007, at 4:06 PM, Roger Lee wrote:

Quote:


Hi Dennis,

Glad everything went ok after the break.
This is why I think everyone should go up and turn the engine off
while in control and practice dead sticks. They are really easy as
you now know first hand. It gves you new confidence that if
something happens it's really not a high stress issue, but only a
landing one.

All cable ends that get pulled on or have stress should be a hot
solder, but a word of caution, do not over heat or apply too much
heat too long. It will cause your cable to become brittle. Just
enough heat to cause the flux to flow and the solder to flow and
then remove the heat. One time when I was doing a hot solder on a
cable I did not like my solder joint at the cable end. I applied
heat too long. When I went to check on the cable strength and
flexibilty it snapped just behind the new solder. Too much heat,
i.e. from a torch, will cause a cable failure. You can use the
torch, but no more heat than necessary to melt the solder.

--------
Roger Lee
Tucson, Az.


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=107946#107946




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PostPosted: Thu Apr 19, 2007 5:58 pm    Post subject: 912 Throttle Cable Failure Reply with quote

At 03:41 PM 4/19/2007, Paul Petty wrote:

Quote:
I know alot of things go through ones mind and Im by no means saying what
I would have done. But monday morning quarter backing I would have called
the "mayday" or anounced my situation to the ground and or traffic and
went WAY out and called "straight in" everybody get the hell out of my way!

My take is that one only calls "Mayday" in a dire emergency, when you need
assistance (whether advice or traffic control) from somebody on the
ground. Not that it hurts... and announcing your situation and intentions
as Dennis is definitely a good thing. Of course at a controlled airport
it's a different thing... "Tower, Kolb one two three kilo is declaring an
emergency..."

I don't agree about the straight in, though. It gives you far fewer
options for adjusting your glide once the engine is stopped. A normal
pattern and approach gives much better control, with the option to widen or
shorten the legs as appropriate.

I had a similar problem years ago in my T-Craft; a pin fell out of the
throttle linkage and left the engine stuck just below the minimum power for
level flight. I was able to make a long slow descent back to the nearest
airport, and made the landing by "blipping" the ignition like a WWI rotary
engined airplane. Of course the prop on a Continental will keep spinning
unless you fly REAL slow and stall the plane, so switching on the ignition
starts it right up again.

-Dana
--
--
My software never has bugs. It just develops random features.


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biglar



Joined: 14 Jan 2006
Posts: 457

PostPosted: Thu Apr 19, 2007 6:49 pm    Post subject: 912 Throttle Cable Failure Reply with quote

I like it. Sounds like a good idea to me. Lar. Do not Archive.

On 4/19/07, Eugene Zimmerman <etzim62(at)earthlink.net (etzim62(at)earthlink.net)> wrote: [quote]--> Kolb-List message posted by: Eugene Zimmerman <etzim62(at)earthlink.net (etzim62(at)earthlink.net)>

I personally would never use a torch to solder a cable. Too risky. It
doesn't take much flame to compromise a cable.
I use a small solder pot I made out of a half inch nut with the one
end welded shut. Heat the nut with torch and fill half full of
solder, flux the cable end and ferrule. Dip ferrule half way into the
molten solder and watch for solder to seep up into the cable strands
above the ferrule, remove and let cool.
Never had one come loose ,,,,,,,, yet.

Gene

[b]


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PostPosted: Thu Apr 19, 2007 8:02 pm    Post subject: 912 Throttle Cable Failure Reply with quote

glad you're not hurt and your bird isn't.

same thing happend to me with a passenger, uneventful.
I was kinda far from my home airport and really wanted to get back there to
do the repair so I just flew it wide open, the tail boom started to shake
sometime after VNE so I angled up some to keep it slowed down a little.
Ended up at 6k over my home airport had plenty of time to figure it out how
to land it. Soon as the engine went off I think I only took one breath of
air the whole way down.

They dont fly like a sailplane.


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DAquaNut(at)AOL.com
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PostPosted: Thu Apr 19, 2007 8:07 pm    Post subject: 912 Throttle Cable Failure Reply with quote

In a message dated 4/19/2007 1:56:06 PM Central Standard Time, Dennis.Kirby(at)kirtland.af.mil writes:


Quote:

Lesson here is: Give appropriate attention to even the LITTLE details
during your building process. That tiny little brass ferrule needs to
be soldered correctly for it to do it's job.

Dennis Kirby
Mark-III, 912ul, 66.6 hrs on the Hobbs when I took off, this flight, in
Cedar Crest, NM

Dennis,
Good to hear a post with a good ending! Keeping your head is a big factor, when there is a malfunction. Wish I had a way to get my Firefly to go wide open if the throttle cable broke. It is quite exciting to have the engine go silent. Your options are less and
that choice has to be made QUICK !

Ed Diebel
**************************************
See what's free at http://www.aol.com. [quote][b]


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Richard Pike



Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

PostPosted: Fri Apr 20, 2007 6:27 am    Post subject: 912 Throttle Cable Failure Reply with quote

CPS sells replacement brass ferrules, and here is how to guarantee the wire
will not pull through. One end of the ferrule is countersunk, the other is
square cut, apparently to make it easier to slip over the cable. Slip the
ferrule on the wire backwards so that the countersunk end is toward the end
of the cable. Now take an Xacto knife and rat tail the exposed end of the
cable. Pull the cable down into the ferrule a bit until it starts to bind,
if it is rat tailed really bad, it can't go through. You ought to have about
1/16" sticking out. Now solder it, the solder will lock the splayed rat
tailed ends in place in the countersink, make it solid so that it cannot
compress, and now you have a cable end that is too big to fit through the
countersunk end of the ferrule, in addition to the solder joint itself.

Richard Pike
MKIII N420P (420ldPoops)

---


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PostPosted: Fri Apr 20, 2007 12:04 pm    Post subject: 912 Throttle Cable Failure Reply with quote

<< Just curious, did you turn L/R base then L/R final with no power? If
you chopped the power as you beaked the numbers how well did she glide
in the 180? Paul P. >>
Paul, and All -

While I still had power, I positioned my Mark-III into the exact spot in
the traffic pattern that I usually fly it, when under power. At 1000'
AGL and abeam the numbers on a downwind leg, I cut the mags.

Quote:
From this point, on a normal approach with power pulled back to near
idle, my plane would continue on downwind another half minute, then turn

base & final, and touch down on the last third of the mile-long runway.

Dead stick, I barely made it to the first third of the runway.

Dennis Kirby


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Roger Lee



Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

PostPosted: Fri Apr 20, 2007 12:59 pm    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Hi Guys,

There are many reasons for an engine out. We have broached this subject once before to practice real engine out dead sticks. The Kolb under idle lands differently from a full engine out. The glide on a full engine out is shorter. Best way to practice so you can be comfortable with them is to be on final and know you absolutely have the runway. Reach up and kill the engine. You are now no different from a glider pilot. Keep up your speed, maybe add 5 mph, fly it to the runway and land. It handles very well and there are no suprises. Land it like you always do. When I practiced mine in the Mark III I would come in at 65 mph no flaps, with 20 flaps I would come in at 55 mph. Go up a few thousand feet and glide around a while just to get comfortable and relaxed. Pretty soon you will think this is fun. You sure won't worry if the engine quits so long as you have a landing site in range. Glider pilots glide and land all the time, I don't know why so many power plant pilots panic and crash when the engine quits. Ahhhh, could it be they never practiced or tried these. The time to practice is before you have a real problem.


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biglar



Joined: 14 Jan 2006
Posts: 457

PostPosted: Fri Apr 20, 2007 2:27 pm    Post subject: 912 Throttle Cable Failure Reply with quote

You make me think of the wire rope chokers we used when skidding logs in Idaho. For on the spot repairs we'd use a cutter and sledgehammer to trim the end of the wire rope square, slip the ferrule over it, then spread the strands as you say, but carefully, so's not to frazzle them. Then we'd insert a tapered, grooved 2 piece plug into the end of the wire rope and pull the ferrule back down over it. Smack it tight a few times with a hammer and go use it. Never, ever saw one slip, and they took enormous impacts and loads. I wonder if such a thing would be feasible for the smaller wire ?? It's the same construction, just a different scale. Lar.

On 4/20/07, Richard Pike <richard(at)bcchapel.org (richard(at)bcchapel.org)> wrote: [quote]--> Kolb-List message posted by: "Richard Pike" <richard(at)bcchapel.org (richard(at)bcchapel.org)>

CPS sells replacement brass ferrules, and here is how to guarantee the wire
will not pull through. One end of the ferrule is countersunk, the other is
square cut, apparently to make it easier to slip over the cable. Slip the
ferrule on the wire backwards so that the countersunk end is toward the end
of the cable. Now take an Xacto knife and rat tail the exposed end of the
cable. Pull the cable down into the ferrule a bit until it starts to bind,
if it is rat tailed really bad, it can't go through. You ought to have about
1/16" sticking out. Now solder it, the solder will lock the splayed rat
tailed ends in place in the countersink, make it solid so that it cannot
compress, and now you have a cable end that is too big to fit through the
countersunk end of the ferrule, in addition to the solder joint itself.

Richard Pike
MKIII N420P (420ldPoops)

---


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Larry Bourne
Palm Springs, CA
Building Kolb Mk IIIC
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jimhefner



Joined: 11 Jan 2006
Posts: 91
Location: Tucson, AZ

PostPosted: Fri Apr 20, 2007 6:42 pm    Post subject: Re: 912 Throttle Cable Failure Reply with quote

Nice going Dennis!! Glad to hear you got your plane down without incident.... looking forward to seeing you at MV soon! It's good that it happend close to home and not enroute to MV!!

I practiced power-off (engine at idle) glide approaches regularly in the Firefly and performed several approaches with engine off.... I found the Firefly glided better and further with engine off than it did at idle. The prop disc was acting like a brake when the engine was still running. I also always did normal approaches, cutting the engine off abeam the runway at different altitudes from 500 - 1000' AGL, adjusting the glide path accordingly. I didn't give away a lot of runway on the glide approach since I had a long runway to play with. I did more of a circling pattern approach than a squared-off base and final. That way I could pick a reference point on the runway (like aiming marks) and always maintain the same relative angle to the ref point, like picking a spot on your windshield and keeping it there on final.

I practiced power off approaches a bunch in the 150 before going for my practical test last month. When the examiner pulled the power I wasn't the least bit nervous... I setup a 65mph glide, went through the emergency checklist and setup for a normal right pattern at a glider airstrip out in the desert west of Tucson. I had the runway made with ease on final and was starting to apply some flaps when he told me to abort the landing. Later the examiner asked me if I had been a glider pilot previously.... Smile I took that as a real compliment. As Roger said, practice, practice, practice!! Don't wait until you have an emergency to practice!! Dennis was lucky to have full power at his disposal... that's not always the case.

Way to go Dennis!!


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Richard Pike



Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

PostPosted: Sat Apr 21, 2007 6:16 am    Post subject: Re: 912 Throttle Cable Failure Reply with quote

After I sent my post on this yesterday, remembered that I had done an article on this for our local EAA chapter newsletter, with some pictures. So here they are. I think the attachments will probably show up in reverse order, but you guys will figure it out.

Richard Pike
MKIII N420P (420ldPoops)


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solderswage4 (Medium).JPG
 Description:
This is what it ought to look like when it's done.
 Filesize:  21.32 KB
 Viewed:  366 Time(s)

solderswage4 (Medium).JPG



solderswage3 (Medium).JPG
 Description:
With the swedge resting on the edges of the vise, pull the cable back down as far as you can, and then solder it. Make sure that the swedge and the cable are both clean and ready to take solder.
 Filesize:  23.82 KB
 Viewed:  396 Time(s)

solderswage3 (Medium).JPG



solderswage2 (Medium).JPG
 Description:
This is what you want the cable to look like as it pokes out. Rat tail the fool out of it, it needs to be so spread out that it can't pull all the way through.
 Filesize:  24.28 KB
 Viewed:  411 Time(s)

solderswage2 (Medium).JPG



solderswage1 (Medium).JPG
 Description:
Here is the fitting that CPS sells. Notice that one end is flat, the other is countersunk. The countersunk end is what the end of the cable pokes out of.
 Filesize:  43.99 KB
 Viewed:  414 Time(s)

solderswage1 (Medium).JPG


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possums(at)bellsouth.net
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PostPosted: Sat Apr 21, 2007 4:35 pm    Post subject: 912 Throttle Cable Failure Reply with quote

At 10:42 PM 4/20/2007, you wrote:
Quote:


Nice going Dennis!! Glad to hear you got your plane down without
incident.... looking forward to seeing you at MV soon! It's good
that it happend close to home and not enroute to MV!!

I practiced power-off (engine at idle) glide approaches regularly in
the Firefly and performed several approaches with engine off.... I
found the Firefly glided better and further with engine off than it
did at idle.


I agree .... my "Semi" Firestar glides better and further with engine
off than it does at idle.
I got three blades, so the disk may effect me more.
Maybe the "Twins" have more drag to deal with than the single seaters?
This was on a day with pretty good thermals and I still don't think
"it drops like a rock" at least not to me - 400 ft per minute?
Sorry about the quality - this was with my old VHS camera converted
to digital, but still.

http://video.google.com/videoplay?docid=-9177096133625180462&hl=en


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