Critical TOPIC, flywheels with integrity problems!

First off, I thank Tim Grider for making available this information on his failure. From what we see here, it is quite apparent that this massive inclusion formed in a rather critical spot. I am quite amazed it ran for thousands of hours before the loud knock of a lose Gib.

Tim was aware, he shut the engine down and investigated! This inclusion appears to have been created by some type of contamination, >possibly< caused by having an in experienced team at the foundry, and NOT removing the slag or other contaminates from the top of the molten metal.

I believe this problem is quite rare, BUT we must assume it will happen again, and we must do all we can to make all persons coming into contact with these engines aware of the fact that a flywheel with a problem and up to speed is little different than a bomb, one of the more obvious differences is you have too little control over the time of explosion! 

If you think it is important to know the brand of this engine, I disagree; this wheel could have been fitted to a number of brands, as Rajkot is little more

than a cottage industry.

It is true that the Stover Wheels are safer, but what we need to do is educate people on ‘ring’ tests, and making every effort to assure a good

wheel is in use. To investigate a NEW Knock in an engine is critical!

Fitting proper guards, fitting a shut down cord so you do not have to reach over the flywheel or align a body part with the flywheel is critical

You are the CEO of your operation, and you have the most control over safety.

If you have any doubts about your fly wheels, it is best you use your Listeroid for a door stop!

As I say on the utterpower CD, it is best you never run one, and if you do, you take >full< responsibility for the safe operation.

To blame others for a failure will not raise the dead!

I have Friends that think it a reasonable idea to sell completed slow speed Gensets to people with less skills than usually found in our DIYer group,

I personally think this design is best left in the hands of mechanics, and those who care to learn how to run them safely.

I received an email just yesterday..

He says he read my warning about over speed, and quickly turned down the governor after the engine might have hit 2000 rpms !!!

He didn’t seem to get the message did he? Indian workers are too lazy to re-adjust the governor to safe ‘unloaded’ speeds after their loaded test.

You will never trust them to do so, unless you're some kind of nut! You will always think the paint is causing interference, you will check these

critical things.

I wanted to tell this guy he needed to learn to read, and ask him why he didn’t ‘back off’ the spring before he ran it as I suggested?

Why wasn’t his hand ready to use the lever to control the speed?

He lived thru a very dangerous operation, and he seems to have no clue that he might have missed out on his next birthday.

Another guy writes a friend of mine and says: “I find George’s Rants and Tirades unprofessional”,

My reply, “Many do find me unprofessional”, and it’s probably a strong indicator that you are NOT part of my target audience. 

I remain focused on the DIYer, and there is no place for a big fly wheel engine of any kind in the hands of careless people, real DIYers are

seldom careless, they've already seen or heard the horror stories.

 Tim Grider, thanks again for helping us learn of this failure, and we are pleased that you are a DIYer and took action to stop the engine and

investigate that knock!

All the best!

George B.