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The Bushcaddy ELSA with Rotax 912 ULS I co-own had a problem awhile back where the CHT got too hot and a piston disintegrated on takeoff. Since the repair we've replaced the oil cooler with a larger one, modified the cowl intake opening for the oil cooler to give the air a straight shot and sealed all around the radiator and oil cooler to force all air thru them and eliminate any air going around. For most of the year the thing runs so cold we have to put lots of tape on both rad and oil cooler just to get to the bottom of the green. Now that we've had a few warmer days we are seeing the CHT's continue to rise up to 245 F on extended climb in OAT of 85 F or more, but oil temp will stay at about 180-190 and the highest coolant temp I've seen is 205 f, and usually no more than 200 even as the CHT is way up there. The CHT's are about the same on both sides, maybe 2 degrees hotter on the right side.

Our Coolant gauge is on the tube after it flows out of the engine. We use Prestone Dex 50/50 pre-mix coolant with a bit of Redline Water Wetter added. It was put in about 9 months ago. The coolant tank is full and there are no kinks in the coolant hoses. One of us did put the rad cap on once with the gasket folded back on itself but we straightened that out and it seems normal and does not leak. The engine is cowled but does not have the Rotax fiberglass shroud around the cylinders. There are no coolant leaks.

I have the redline for the CHT marked at 249 F on the VDO analog gauge. Is that correct? And if so, why would the coolant be nice and normal while the CHT's are so close to redline? We are having to really keep an eye on this and level out and circle around when trying to climb over the mountains. Much of the summer we will be seeing temps over 100 degrees at the airport (SZP) where the airplane is based, so this is just going to get worse. I'd hate to lose a piston while crossing the mountains. Any suggestions?
  • Re: High CHT's on extended climb, but low coolant temp

    by » 12 years ago


    Hi Gary,

    I hope your using 91+ octane in your engine? You may be getting detonation and think its just hot. Where are the clips on the carb needle positioned at? #3 is normal which is third notch down from the top. Fuel is the #1 cylinder cooling agent. The coolant and air are more secondary.

    It would be very helpful to know what the EGT's are, more so than the CHT's. This will help tell us what's going on inside the cylinder during the burn. Too lean, just right or too rich info.
    It is possible to have some air in your cooling system. The 249F max for 50/50 is correct. What do you have the plug gaps set at? The hotter the OAT the wider the gap. Cold OAT's get narrower gaps. I wouldn't panic at 245F, but wouldn't let it keep rising at a fast or unchecked rate. What is your wide open throttle rpm when flat and level? If the prop is over pitched it will cause high temps. You may need to flatten the pitch some to reduce engine work load.

    One way to help when the OAT's get high is to reduce flaps on take off and make the climb more shallow.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: High CHT's on extended climb, but low coolant temp

    by » 12 years ago


    Thanks Roger!

    We use 91 octane mogas and try to keep it fresh. Flat and level RPM at 3500 feet is 5800.

    I don't know what position the carbs are in but when I gapped the plugs last I did them on the tight side of the range. So maybe that is a factor. We don't have EGT gauges, but it looks like maybe we should.

    Gary

  • Re: High CHT's on extended climb, but low coolant temp

    by » 12 years ago


    Hi Gary,

    EGT's are good to have. I would open the gap to .027. I would double check the carb needle clip position too. I would put the carbs on a set of gauges too too see if they are synced. It's just all part of the process to check.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: High CHT's on extended climb, but low coolant temp

    by » 11 years ago


    Thanks Roger. Before seeing your final message that said .027 we went out and gapped the plugs to .025. They were previously at about .035 if I recall correctly. But on our test flight it was even worse than before. We had synced the carbs in January and it still runs very smooth 50 hours later, even at low idle where you are not supposed to go. Then we test flew it at 6:00 A.M. when OAT was 65 f. While in pattern altitude, abeam the numbers CHT was up into the yellow, running about 4800-5000 RPM. We then flew it about 15 miles East (away from the cool ocean) where it was 86 f OAT, climbing very gradually from 850 feet to 2000 feet. When CHT climbed to 245 f we gave up and turned around, reduced power and pointed the nose slightly down. CHT continued to rise for a short time, all the way to redline and then came down below yellow as we descended. The whole time the coolant and oil were nice and cool, which just makes no sense to me. I was convinced that the CHT gauge was bad so I sent it to the manufacturer to be checked. But it was fine. Both sensors read within a few degrees of each other, so a bad sensor seems unlikely unless they both failed simultaneously. The day we flew we had 10 gal of new Premium fuel and the balance of it (probably another 10 gal)was 2 weeks old. For the next test we did a cold start another day, intending to see if the water pump was pumping/flowing unobstructed. I pulled off the radiator cap just after start-up and could only see water vibrating so stuck my finger in the coolant. Within a short time I could feel it heating up, making me believe it must be circulating fine.

    Can I check the position of the carb rods you mentioned without goofing up the carb sync?

    It was working fine a few months ago. We flew it to Taft California, with two of us on-board and full fuel, where it was 99 f, and had to climb to 9500 feet to cross 2 mountain ranges with the valley between them at over 100 f OAT. We did have to level out a few minutes once while climbing as it got to mid yellow after a long hot climb, but nothing like now. When we departed Taft the CHT got to mid level on take-off until we climbed to where OAT was about 95 degrees, then it was fine all the rest of the way, even climbing up to 9500 feet again. The only thing I can see that is different is that some of the aluminum tape around the radiator to force incoming air thru the radiator had pulled loose. I have since applied new/better tape, but since the coolant was cool I can't see where that changed anything. Still stumped!

    Gary Van Meter
    Rotax 912 ULS in a Bushcaddy R-80 ELSA

  • Re: High CHT's on extended climb, but low coolant temp

    by » 11 years ago


    Hi Gary,

    Something has changed and we need to figure out what. I don't quite understand why the coolant would keep cool while the CHT temp kept climbing. They should be climbing or declining somewhat together. The coolant cools the heads so they are within several degrees, but shouldn't have a huge spread.

    I just re-read your post.
    You don't still have tape on the radiator do you? If so yank it off. No tape for warm months. It may be the difference on where the coolant temp is sampled and where the CHT temp is sampled. Pull the tape and try again.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


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