REFLECTOR: Investigation into Engine Failure

Fri Feb 20 10:56:48 CST 2009

Hi John-

Have you checked with Subaru- they should have some .030 over pistons
available- nothing wrong with the stock units- I can not remember if you
have a turbo or not though- really, with many discussions with a lot of
unhappy Crossflow customers- it all comes back to the ECU causing the
problem- Jorge made a poor choice in that DTA unit, and everyone is paying
now- please consider the RWS ECU- it is under $800, has built in redundancy,
and you can sell the old DTA unit on line for about $700- so cost is offset-
you will need to hand-make a new harness, and attach corvette coils, but I
have been down that road, and it is not that hard really-   I can't remember
- do you have a 4 or 6 cylinder unit in your project?

Other thing about Tracy Crook- he is almost always available (even on
Saturdays) and really wants to help- bit difference from Crossflow...

Alex

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From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org] On
Behalf Of JOHN LUNNING
Sent: Friday, February 20, 2009 8:44 AM
To: reflector at tvbf.org
Subject: Re: REFLECTOR: Investigation into Engine Failure

Hi Alex
Not doing too good with the engine rebuilt. If you can believe it, I'm still
waiting on pistons after 6 month. I'm told there has been a major
manufacturing problem at the Piston company that has caused a big backlog.
So I'm still waiting. I've completey run out of hope and drive to keep on
going. Not sure what I'm. Keep me informed on the performance of the ECU.
Which version of ECU are you using?

John

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From: velocity_pilot at verizon.net
To: reflector at tvbf.org
Date: Wed, 18 Feb 2009 20:39:21 -0600
Subject: Re: REFLECTOR: Investigation into Engine Failure

Hi John- just to update- got Tracy Crooks unit installed and running
finally- runs great so far- need to put more time on though- how are you
making out?

Alex

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From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org] On
Behalf Of JOHN LUNNING
Sent: Tuesday, August 05, 2008 8:58 AM
To: Velocity Aircraft Owners and Builders list
Subject: Re: REFLECTOR: Investigation into Engine Failure

Hi Alex,
It's been a real struggle trying to get the engine rebuilt. I had to have
the cylinders bored out .030 over to clean up the damage. Finding pistons
has been a challenge. It appears that Crossflow used stock Subaru pistons
which are cast pistons and are not recommended for turbo charging. I'm now
having some custom forged pistons made. Machine shops now a days don't seem
to be in much of a hurry to do anything. I have  a few mods planned to help
cool things better, but there is still the root issue of the ECU and its
programming. I'd be interested to know more about your ECU and how it's
doing.

All the damage to the airframe are repaired, just waiting on the engine
rebuild. Once I get the engine put back together, I'll update you more.

John

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Date: Mon, 4 Aug 2008 23:28:28 -0500
From: velocity_pilot at verizon.net
To: reflector at tvbf.org
Subject: Re: REFLECTOR: Investigation into Engine Failure

Hey John-

Any other update on your situation? I have chosen to replace the ECU I
bought from Crossflow with Tracy Crooks unit- has dual ECU's and programs
from a small panel without need for laptop- uses less sensors too- let me
know what the outcome was on your unit if you get a chance.

Thanks,

Alex

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From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org] On
Behalf Of JOHN LUNNING
Sent: Tuesday, February 05, 2008 5:17 PM
To: reflector at tvbf.org
Subject: REFLECTOR: Investigation into Engine Failure

For those who are interested in the failure of the Crossflow Subaru engine
on the 2nd flight of my VelocityXL. Initial investigation of the engine is
showing an internal mechanical failure in the engine. I'm getting low
compression on a couple cylinders and I'm get burnt oil out of the crankcase
vent on one side. The engine did fire up again but was running very rough
and I could hear mechanical tapping noises from inside. All external systems
appear to be in good working order, fuel system and fuel pumps good with
good pressure. The electrical and computer seem to be working correctly. I
won't know too much more until I tear it down in a couple weeks.

As usual for Crossflow, they were very quick to respond when I told them the
good news about my 1st flight, but have yet to be able to get a hold of them
to discuss the failure of the 2nd flight. I doubt highly if I will get any
factory support in diagnosing and repairing the problem. Strong possibility
I may have to abandon the project if I can't get the engine to run reliably.
I'll be starting on the leading edge damage this weekend and should only
take a couple week to repair.

Take warning to all those who have or are considering Crossflow for your
engine. For those who are stuck, I'll be happy provide any support or info
you might need.

John Lunning
N44VL
San Antonio, TX

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