Saturday's are always busy, and one with perfect weather, very. I was there for almost 4 hrs and got maybe 4-5 flights. I took the Pulse XT60 and the Ultrastick out. I just flew and didn't bother with pics or video.
As I was getting ready for the first flight of the Pulse XT60 I warmed up the engine and thought the cowl was really shaking (I think I saw the muffler jiggly too). Had a nice flight. As I was setting up for a second flight I realized I didn't have two US 4-40 screws (I think that's the size) and that's why the cowl was loose. I taped the loose side and taxied out to the runway. As I turned to take off I saw the muffler was really dancing so taxied back and saw it had come lose. I taxied back to the bench. A flying buddy, Larry, gave me two screws for the cowl (he has a small hardware store in the back of his car). I removed the cowl to fix the muffler and being rear mounted I would need to remove the engine. I really wasn't in the mood to do this at the field, I came to fly, so I set the Pulse aside for the day.
Flew 2-3 flights on the Ultrastick over the next 2-1/2 hrs (a lot of waiting my turn). I had it dialed in. At the end of my last flight I realized I was getting tired and my vision unreliable (cataracts, need good lighting and cloud clover was moving in). I wisely called it a day.
You can see the muffler hanging loose. One bolt still attached. Thought the other lost but it fell out of the cowl when I removed it. Pulled the engine, reinstalled the bolts with a friction lock washer and some thread lock. This one always shakes loose. This is an real RCGF 20cc (which Joe Nelson told me is actually a 26cc). The muffler has come loose on this engine a few times
One thing I later noticed as I worked on the firewall for the MX-Bach, is that the exhaust tube got bent back. It's straight back, no cracks. I forgot to look but I think this 35cc is a DLE. It doesn't need replacing, which is good as I can't afford one right now.
The firewall is coming along nicely. Had to Dremel and hack saw the notch flanges at the four sides. Tomorrow I will drill it for mounting the engine, the center hole for the fuel lines and a small hole for the throttle control rod. I had to cut the original one to get the engine free of the firewall, so I'll be making a new one. I noticed that the flange holes on the engine box to which the fire wall gets attached did not appear to have epoxy in them... I am not sure why, though I see this on landing gear hard points that are also installed using flanges so that it can break out clean. Is this what they had done with the firewall? I am not sure I will, I think I will epoxy all the way around. If this plane crashes again I don't expect it to survive, and I would just as soon the engine breaking free in flight not be the reason it crashes
I knew I had a large set of aluminum landing gear. They were not drilled so I was able to custom drill them. Here they are installed. They are curved, which I don't think I have ever had on a plane before. Terribly upset the carbon fiber ones were broken in the crash. These I'll work great!
Tomorrow I will install the firewall and the engine. Then I will need to repair the under cowl and the canopy. I got some metal L brackets I may use to repair the cowl mounting tabs, but that's an idea still in the works. This hasn't been too difficult a repair so far.
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