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Gouged Cylinder Intake Flange

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VF84Sluggo

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After removing all the residue from the old intake gasket, I discover a gouged flange. (I can assure that I did not do this.) I've been troubleshooting an induction leak(s), wonder if this is part of the problem?

Again, this is the Sky Dynamics cold-air induction system, uses o-rings for the seal. But someone before I owned this plane used o-rings and gaskets.

Any suggestions here?
 

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If you want a smoother finish, take a fine flat file and carefully resurface that area.
 
I'm thinking something should be done. Seems like it's a place for an induction leak to happen. Trying to not have any of that anymore.
 
I would cover the flat surface with some Dye-Chem, then start with a flat sharpening stone to see what starts to come off. You should be able to use various grits to get the surface flat and smooth. A file might be too aggressive.
 
The more I think about this, this looks like something I could really screw the pooch with by messing with it. Go from bad to worse.

I think I'll have our local maintenance shop come take a look, see what they think, what they can do.
 
I would cover the flat surface with some Dye-Chem, then start with a flat sharpening stone to see what starts to come off. You should be able to use various grits to get the surface flat and smooth. A file might be too aggressive.

I agree. I never should have assumed that you would know how to use a fine file for this application. Any machinist can demonstrate the proper way to surface this area with a proper file.

A sharpening stone can show what needs to come off. But you will need to pack a lunch if you expect the stone to give results in a timely manner.

If you are using an "O" ring, I do expect it to seal that surface. Close the intake valve and install the intake tube facing out. Connect the exhaust of a shop vac and soap the flange area, looking for bubbles.
 
If you are using an "O" ring, I do expect it to seal that surface. Close the intake valve and install the intake tube facing out. Connect the exhaust of a shop vac and soap the flange area, looking for bubbles.
Good plan. I'll do this first, then go from there if I can't get a good seal.

This Sky Dynamics system does use o-rings. But as I've posted, at some point someone used gaskets in addition to o-rings. Have no clue why, don't think that is correct. From what I gather, since the pipe flanges have the groove for an o-ring, an o-ring is the only thing you should use for the seal.
 
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If you are using an "O" ring, I do expect it to seal that surface. Close the intake valve and install the intake tube facing out. Connect the exhaust of a shop vac and soap the flange area, looking for bubbles.
Did this check this morning as you recommended.

First thing I noticed was that the current o-rings didn't seem to be the correct thickness. Tried anyway, bubble test failed.

Removed that that #2 cylinder intake pipe and went to the FBO. They had gaskets that were thicker and were a drop-in fit. Repeated bubble-test: perfect. No leaks at all.

Thanks for the tip!
 
My stock intake collars were all jacked up due to someone tightening them too much. Used some 120 grit on a piece of granite and BOOM nice and flat
 
My stock intake collars were all jacked up due to someone tightening them too much. Used some 120 grit on a piece of granite and BOOM nice and flat
Did you sand the entire flange/collar so that the face stayed 'level'? That's my concern with only sanding/filing the gouged area, that that spot wouldn't be even with the rest of the flange.
 
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