Sun 'n Fun Report
2022
Subject: ElectroAir D2000 Replacement Certified
ElectroAir was very pleased to announce at Sun 'n Fun Tuesday that their electronic ignition D2000 replacement system has finally been certified by the FAA. This consists of an electronic magneto sensor for four spark plugs, that installs in the magneto mounting location, and a crank position sensing ring and sensor that install around the crankshaft just aft of the prop and on the crankcase near that location, respectively, for the other four spark plugs (the redundant mag). In addition, there are four coil assemblies and a processor that require location somewhere near the engine.
Still pending but almost in hand, ElectroAir president Michael Kobylik reports, is FAA approval of the TCW backup battery to power one of the two electronic mags, just in case. Use of the TCW battery will require a switch panel with a voltage indicator and control switch.
Michael Kobylik assures me that production units will say "Backup Battery" and not Backup Batter, though I suggested that he could sell the first run of Backup Batter switch panels by including some chocolate chip cookie dough batter with the deal. I asked Michael about the FAA "issue paper" on backup power for electronic ignition systems, and he promised to provide us with a copy if the FAA allows him to do so.
>> I am really confused on this. What changed? Isn't this where they were months ago, when everything of theirs was approved, but the FAA wanted a named battery or second alternator included in the STC?
>> I hope this approval might mean that the SureFly second EIS with backup battery may be similarly be getting closer to FAA 'approval'? Perhaps with similar batter panel!
I don't think they actually had the STC for the D2000 replacement, now they do. If you already have a second alternator or battery somehow, you'd be good to go.
The ignition system price is $4,995, show price $4,495. Show price available to CFO members through 4/30/22.
Certified TCW battery system price $1,165 ($200 adder for 24 volts). Includes the control panel.
TCW Technologies, Integrated Battery Back-up System (IBBS) The Integrated Battery Back-up System (IBBS) provides an engineered solution to enable an endurance bus for critical loads found in aircraft. The IBBS system provides back-up power to critical electronic loads such as EFIS, GPS, Autopilots and engine.
Information: http://www.electroair.net
Orders and Support: http://www.smoothpowerllc.com
Backup batter(y) power: http://www.tcwtech.com
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Subject: Airbag Breakthrough, Universal Retrofits
There has been another breakthrough in the world of saving lives in general aviation airplanes. AmSafe has gone a step beyond its custom seatbelt airbag system-individually designed and built for over 150 types of general aviation aircraft-and developed a "universal" seatbelt airbag system that can be installed on almost any seat in almost any general aviation airplane.
So as Cardinal owners, we have a choice: The STC'd system for the Cardinal, or for about half price, the generic system.
While that is great news for occupant safety, the better news is that this universal retrofit-entitled SOARS (State-of-the-Art Restraint System)-is less than half the price of the bespoke system that has been going into airplanes since about 2004. A universal retrofit potentially means a drop in the number of fatalities and serious injuries in general aviation airplanes because very sophisticated occupant protection is available at a startling low price-$2580 for two seats, plus three to six hours to install.
https://www.amsafe.com/20988-2/
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Subject: What's New at WILCO?
Mike Hattrup from WILCO gave us an update, talking a bit about their new corporate parent Aeromach, and the origins of the business in $13 million of surplus parts purchased from Piper so long ago. WILCO itself began in 1953, and Aeromach in 1971. They are distributors of Concorde (2 year warranty), Whelen, RAPCO, Lamar, PM Research, Barry (including now engine mounts for *both* FG and RG), and always offer a CFO discount that's comparable to their show discounts. The biggest product now is the Whelen G3 landing light, now available in both PAR36 and PAR46, with 2.5 times the light, and a CFO price of $279, plus five year warranty. https://www.wilcoaircraftparts.com/
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Subject: New, brighter Whelen landing/taxi lights
Whelen Aerospace introduced the new Parmetheus G3 in PAR46 size at Sun 'n Fun. This follows the PAR36 introduced last summer at Airventure. The G3 series are dual voltage so they will work on both 12 and 24V aircraft. They come with Whelen's 5-year warranty, and are the brightest on the market short of HID. The PAR36 are 150K candela and the PAR46 is over 200K candela. CFO sponsor Wilco is well stocked on both sizes. Pricing is under $300 and $400 respectively before your CFO discount.
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Subject: Superior Cylinder Backlog
Superior reports they are currently taking orders for parallel valve cylinders for delivery in Feb 2023.
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Subject: Concorde Battery Update
Concorde has a several month delay in shipping batteries when ordered today. They have good material supply, but demand is way up. However, CFO sponsor WILCO has standing inventory replenishment orders, and so will have batteries in stock in April. So start with Wilco!
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Subject: S-Tec 3100 and Aspen Max – happy together at last?
STEC says that they have made adjustments to the 3100 software to properly operate with the Aspen Max. It has been deployed with a service letter. All Cardinals that they are aware of are now operating correctly and holding altitude smoothly. If you need help with your dealer's understanding of this situation, contact Al Rice, Field Service at STEC.
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Subject: GAMIjectors and Engine Change
GAMI shared the opinion that converting an IO-360-A1B6D to an IO-360-A1B6 may change the injector tuning balance. They suggest re-running the GAMI test and sending them in for tuning if required. They also pointed out that if a new engine is installed, the STC would need to be updated with the new engine serial number. www.gami.com
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Subject: Monarch Cap Backlog
The maker of Monarch gas caps (Hartwig) reports that certain of the parts of their fuel cap system come from China, and they expect that it will be 18 months or more before they can deliver new caps. In the meantime, they are able to rebuild or refresh caps currently in use. http://www.hartwigfuelcell.com
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Subject: Desser Tire Inventory Recovers
Desser Tire was asked about recent reports of difficulty getting aircraft tires and tubes. They said that there was a little trouble for a while, but they have worked through those issues, and we should not currently have any difficulty getting tubes or tires.
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Subject: Aircraft Values & Insurance Gotcha
Keith reported that insured hull values are up significantly, maybe 40%, due to the surge in used aircraft prices during COVID lockdown. Keith offers market evaluation (not an appraisal) to support higher insurance limits. Paul shared how his undervalued aircraft cost him money after the gear-up landing.
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Subject: Door Latch Sprague Clutch Repair
Roy Sobchuk offers repair of Sprague clutches for Cardinal door latches, and that AviationPlus' Bob Russell keeps these in stock, and can accomplish repairs as well. Bob also reports a new repair for cracked vertical stabilizer bulkheads.
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Subject: Can my RG Cycle the Gear as Quickly as a '78?
Karl Thomas reported on the group effort to source a new electro-hydraulic gear pump that operates '71 through '77 RG gear at the twice-as-fast '78 RG rate. Jerry Olsen is working on a supplementary fluid reservoir that resides below the stock reservoir, and so can't be depleted by the gear pump running into a leaking up-hose... so the reservoir volume remains available to pump the gear down. A DER is being sought to assist with the approval.
One other member reported success in installing a robust voltage doubler between the aircraft wiring and the 12 volt RG pump... operating the pump motor at 24 volt in 10 second bursts (normal gear up/down cycle timing) appears not to have deleterious effects, but it does accomplish the 7 second gear cycle of the '78 without other modification.
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Subject: Carrythrough Spar Corrosion AD?
Carrythrough spar corrosion continues to be a focus. It's unclear what the FAA might do with respect to an AD, but it does seem that the FAA recognizes that the facts and circumstances surrounding the Cardinal spar are different than those affecting the similar-design but different context 210 spar. (Unlike the 210, the Cardinal spar is not afflicted by OEM glued-on upholstery pads that retain moisture, nor by dissimilar metal straps to attach the headliner). It's been a year since commenting closed, so optimism continues.
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Subject: GAMI G100UL Update
Principals Tim Roehl, President, and George Braly, Chief Engineer, updated a packed room on the status of their unleaded avgas development effort. The FAA has delivered GAMI two letters, the first memorializing that G100UL has met all the requirements for issuance of an STC; the second pointing out that GAMI was legally entitled to an STC under the law for complying with all the requirements. However, FAA HQ has ordered the Aircraft Certification Office to refrain from issuing the STC, while a seventh (!) review is performed. GAMI is quite frustrated, as the ongoing review, by a Technical Advisory Board (TAB) violates the terms and conditions setup for such reviews by Congress, and the FAA hasn't even bothered papering over the inconsistency with administrative law procedures... the review is plainly contrary to law and regulation. Nonetheless, GAMI is cooperating with the review, with hopes for an early May resolution, per the FAA's assurances. GAMI went in to long detail on the 13 year certification effort, and reiterated that their fuel is suitable (and will be approved) for every spark-ignition aircraft engine and airframe in the FAA database; they intend to leave no engine on the ground.
The next phase of the process is scale-up with major fuel producers. That timeline is uncertain, since understandably, folks defer investment and decision making until FAA paperwork is in hand. But GAMI promises not to relent. www.gami.com
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Subject: AirSync – Put your Cardinal in the Cloud
Air Sync offers a connection from your airplane to the cloud, to make available a variety of information including fuel levels, warning of engine parameter exceedances, etc. to their smart phone app or the web. Currently, they support only Garmin platforms. Hardware is $795, including the cell modem. After the first year, connectivity costs $200/year. https://www.air-sync.com
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Subject: Uh-oh, Stripped the Threads
Gardserts… FAA approved self-tapping thread repair. We commonly think of the Helicoil inserts that provide a home for our spark plugs. But Gardsert makes an entire line of stainless-steel threaded inserts to repair damaged threads in a number of places on the engine or aircraft. They can even repair pipe thread connections. www.gardspecialists.com
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Subject: How Much for That Hose?!
There's been significant concentration of aircraft hose manufacturing, as one player has bought up a number of hose shops over COVID-time. Herber Aircraft Service in El Segundo CA near LAX points out that they're still independent, and working hard to offer better pricing and delivery time than the aircraft hose collective. www.herberaircraft.com
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Subject: Lycoming EIS – SureFly's Little Brother
Lycoming's Electronic Ignition System. You'll recognize the form factor, it's the SureFly box. But inside, Lycoming has their own firmware, and in fact, they're simplified installation (and reduced functionality slightly) by removing the induction system connection... so unlike SureFly, there's no vacuum advance. Lycoming touts that there's no service life limit to the electronic ignition, and that it's FAA approved "in both single and twin EIS configurations at the engine level." It's not completely clear what that means, except that a redundant power supply is required for the second EIS, either a second alternator or a second battery. ElectroAir is working with TCW to obtain FAA blessing of that avenue for redundant power. It's not clear what Lycoming's strategy is. www.lycoming.com/eis "The Lycoming EIS was developed by SureFly Partners, Ltd. with input from Lycoming's engineering teams to meet Lycoming's exacting specifications. With over two years of research and development, including exhaustive endurance and durability testing, the Lycoming EIS is the only electronic ignition system on the market with the proven performance necessary to bear the Lycoming name."
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