Ernesto Sanchez wrote:


From: Damon Meyer
To: cozy_builders@mailman.qth.net
Sent: Saturday, April 23, 2005 7:56 PM
Subject: COZY: Engine Failure!

Hi all,

My wife Lisa and I and I were flying to Virginia yesterday morning
when our #1 cylinder exhaust valve broke at 6000' between Long Island

MacArthur and Republic field. Lots of instant vibration and noise
accompanied by an RPM drop from 2500 to 2100 RPM. I throttled back to 1800
and got a quick clearance into Republic for a precautionary landing,
checking mags and watching temps on the way in.

We were on the ramp and shut down within 6-7 minutes, and had the
plugs out and a mechanic (Paul Shakalis) looking at it within an hour.
BAD NEWS. The spark plug from #1 looked unhurt, but a huge chunk of valve

had been hammering around in there long enough to make the piston look like
someone had taken a claw hammer to it. Metal in the oil screen, therefore
metal throughout the engine. It was only a matter of time - and probably
very little - before the engine would have died completely. We were very
lucky in all regards.

We dragged the plane over to AirEast, where owner Mike Tarascio was
kind enough to take on the disassembly and inspection task on the O-290.

Lisa and I rented a car and drove back to Maine, and are shipping him the
O-290 overhaul manuals that came with the plane when we bought it last year.

I am sure I'm not the first person on this list to suffer an engine
failure - if anyone here has a line on an O-290-D or an O-320 that
might fit in our Cozy III, please let me know. And/or any advice for how

to get an engine from probable junk status to reliable and safe without
spending $15,000 (that I don't have) would be appreciated. If anyone wants
to see a nice Cozy on static display it's behind the AirEast hangar at
Republic until I find out the extent of the damage and plot a course of
action.

Sad day, but could have been much worse.

Thanks,
Damon Meyer

I guess this proves beyond any doubt that exhaust valves are undesirable

in aircraft.

Don Sherman

You got it. Absolutely the highest stressed piston engine part.

Paul Lamar

-Hurant Karibian wrote:

I'.ve got an O-290 that is all -D2 except for the "G" accessory section and
adjustable rocker arms. It has a Japanese auto starter and alternator plus
all the accessories.About 300-350 hours since rebuild ( would have to check
the log book) $3000.00 plus shipping.

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