Hi Andy, I have seen on one occasion on a very high time engine with over 3000 hrs one cylinder head develop a casting pin hole leak right in the cylinder head exahust valve port near the exhaust valve guide. Because it only leaked when the engine came up to temperature and the coolant was burned off in the exhaust it was a real tough one to find. In this case the cylinder head had a million thermal cycles on it, certainly not your situation but a poris casting is always possible......good luck on that one, lets us know what you find. :huh:
I have just heard from the aircraft manufacturer that the Rotax importer has checked everything over and (apart from one float level being slightly wrong) could find no problem. I will get the aircraft back next week and see how it goes.
Ralph - how was the porosity in your cylinder head found?
My engine has had the coolant system pressure tested but this must have been done cold. I can imagine that at running temperature a small void could open up and give leakage which will not be detectable when cold.
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