DG-200 Water Valve

[S. Murry]

One off the dump valves on my DG-200 is not completely closing. It seems
that the spring mechanism that pushes down on the plug to seal it when you
close the dump valve doesn't have enough "oomph" to completely close the
valve. I suspect that a good cleaning might be all that is required, but
if not I might need to replace the spring or make some other repair to the
mechanism.

The valve assembly is housed inside a plastic box in the wing root. The
box is secured by a number of screws. In order to remove the box, you
need (as one of my club-mates observed "Little Elphin Hands."). I don't
have elphin hands, but I do have a large variety of tools with which to
attack this problem.

However, having never removed this valve assembly before, I am looking for
tips or pointers, specifically:
1) Any easy way to remove the screws?
2) Once I get the screws off, what's inside the plastic box? Am I going
to little springs and ball-bearings flying out all over the place once I
loosen the last screw?
3) Anybody have a picture/drawing/procedure related to the valve
assembly?
4) Anything else I should know?

Any and all tips are greatly appreciated.

--
Stefan Murry

[JohnDeRosa]

Suggestion: purchase the "Elfin Hands" service contract from DG. Only
E1,000 a year. (sorry couldn't help it) (actually this is gallows
humor as I am a DG owner).

I have no experience with DG's internal mechanism other than at a
contest a few year's back a pilot had a leaky/drippy valve and used
vaseline to get the rubber seal to seat itself better. Wouldn't hurt
to give that a try before opening the plastic "pandoras box".

Good luck and let us know how things worked out. Post a picture or
two or three.

- John

[S. Murry]

John,

Thanks. Actually, I think the previous owner may have already used the
"vaseline trick", maybe too many times. I appear to have a
semi-fossilized covering of what appears to be a vaseline/dirt mixture. I
think this is actually what may be gumming up the works. However,
cleaning it from the outside hasn't proven easy.

Well, if nobody else chimes in, I guess I dig in and hope for the best!
I'll certainly post again with results.

--Stefan

On Fri, 02 Dec 2011 13:24:19 -0600, JohnDeRosa > wrote:

> Suggestion: purchase the "Elfin Hands" service contract from DG. Only
> E1,000 a year. (sorry couldn't help it) (actually this is gallows
> humor as I am a DG owner).
>
> I have no experience with DG's internal mechanism other than at a
> contest a few year's back a pilot had a leaky/drippy valve and used
> vaseline to get the rubber seal to seat itself better. Wouldn't hurt
> to give that a try before opening the plastic "pandoras box".
>
> Good luck and let us know how things worked out. Post a picture or
> two or three.
>
> - John


--
Stefan Murry

[Marc]

On Dec 2, 4:13*pm, "S. Murry" > wrote:
> John,
>
> Thanks. *Actually, I think the previous owner may have already used the
> "vaseline trick", maybe too many times. *I appear to have a
> semi-fossilized covering of what appears to be a vaseline/dirt mixture. *I
> think this is actually what may be gumming up the works. *However,
> cleaning it from the outside hasn't proven easy.
>
> Well, if nobody else chimes in, I guess I dig in and hope for the best!
> I'll certainly post again with results.

DG does sell a valve rebuild kit, which, as I remember, consists of a
replacement spring, O-ring, and a few other random parts. This did
the job when one of my DG-600 valves started leaking. I didn't do it
myself, so I can't help you there, and you'll likely have to pay the
DG tax to get hold of the kit...

Marc

[S. Murry]

Thanks, Marc.

I don't think 1500+ dollars for the rebuild kit is in the cards (1000
euros for the "service contract" + a couple hundred for the rebuild kit,
with shipping). So, wish me luck as I dig in myself...

--Stefan

On Fri, 02 Dec 2011 20:50:03 -0600, Marc > wrote:

> On Dec 2, 4:13 pm, "S. Murry" > wrote:
>> John,
>>
>> Thanks. Actually, I think the previous owner may have already used the
>> "vaseline trick", maybe too many times. I appear to have a
>> semi-fossilized covering of what appears to be a vaseline/dirt mixture.
>> I
>> think this is actually what may be gumming up the works. However,
>> cleaning it from the outside hasn't proven easy.
>>
>> Well, if nobody else chimes in, I guess I dig in and hope for the best!
>> I'll certainly post again with results.
>
> DG does sell a valve rebuild kit, which, as I remember, consists of a
> replacement spring, O-ring, and a few other random parts. This did
> the job when one of my DG-600 valves started leaking. I didn't do it
> myself, so I can't help you there, and you'll likely have to pay the
> DG tax to get hold of the kit...
>
> Marc
>


--
Stefan Murry

[eric keetels]

On 3 dec, 18:03, "S. Murry" > wrote:
> Thanks, Marc.
>
> I don't think 1500+ dollars for the rebuild kit is in the cards (1000
> euros for the "service contract" + a couple hundred for the rebuild kit,
> with shipping). *So, wish me luck as I dig in myself...
>
> --Stefan
>
>
>
>
>
> On Fri, 02 Dec 2011 20:50:03 -0600, Marc > wrote:
> > On Dec 2, 4:13 pm, "S. Murry" > wrote:
> >> John,
>
> >> Thanks. *Actually, I think the previous owner may have already used the
> >> "vaseline trick", maybe too many times. *I appear to have a
> >> semi-fossilized covering of what appears to be a vaseline/dirt mixture..
> >> *I
> >> think this is actually what may be gumming up the works. *However,
> >> cleaning it from the outside hasn't proven easy.
>
> >> Well, if nobody else chimes in, I guess I dig in and hope for the best!
> >> I'll certainly post again with results.
>
> > DG does sell a valve rebuild kit, which, as I remember, consists of a
> > replacement spring, O-ring, and a few other random parts. *This did
> > the job when one of my DG-600 valves started leaking. *I didn't do it
> > myself, so I can't help you there, and you'll likely have to pay the
> > DG tax to get hold of the kit...
>
> > Marc
>
> --
> Stefan Murry- Tekst uit oorspronkelijk bericht niet weergeven -
>
> - Tekst uit oorspronkelijk bericht weergeven -

Hi Stefan,

Do you have a waterballast system like this: http://www.mijnalbum.nl/GroteFoto-KDTAVP3R.jpg
I changed the spring without any problems. It's easy to do.
The size of the spring isn't really that critical, mine comes from a
friends "collection".
You might find one a regular hardware shop.
I made a photoshoot of the whole operation.
Just let me know if you need more details.

Best Regards,
Eric
(the Netherlands)

[S. Murry]

Eric,

Thanks for responding. Unfortunately, my system appears to be different.
Basically, I have a cable (similar to a bicycle brake cable) that connects
to a thin rod which runs out the fuselage into the wing root. In the wing
root, this rod is connected to a metal arm. The axle of this arm runs
into a plastic box.

Inside the box I have no idea.

However, through some magical system, this box converts the linear motion
of the rod into a linear motion of the plug that seals the drain port.

I suspect that there shouldn't be much more than a spring inside the box,
and of course the drain plug assembly, but I guess I'll find out once I
open it!

--Stefan

On Sat, 03 Dec 2011 12:32:20 -0600, eric keetels
> wrote:


>> On Fri, 02 Dec 2011 20:50:03 -0600, Marc > wrote:
>> > On Dec 2, 4:13 pm, "S. Murry" > wrote:
>> >> John,
>>
>> >> Thanks. Actually, I think the previous owner may have already used
>> the
>> >> "vaseline trick", maybe too many times. I appear to have a
>> >> semi-fossilized covering of what appears to be a vaseline/dirt
>> mixture.
>> >> I
>> >> think this is actually what may be gumming up the works. However,
>> >> cleaning it from the outside hasn't proven easy.
>>
>> >> Well, if nobody else chimes in, I guess I dig in and hope for the
>> best!
>> >> I'll certainly post again with results.
>>
>> > DG does sell a valve rebuild kit, which, as I remember, consists of a
>> > replacement spring, O-ring, and a few other random parts. This did
>> > the job when one of my DG-600 valves started leaking. I didn't do it
>> > myself, so I can't help you there, and you'll likely have to pay the
>> > DG tax to get hold of the kit...
>>
>> > Marc
>>
>> --
>> Stefan Murry- Tekst uit oorspronkelijk bericht niet weergeven -
>>
>> - Tekst uit oorspronkelijk bericht weergeven -
>
> Hi Stefan,
>
> Do you have a waterballast system like this:
> http://www.mijnalbum.nl/GroteFoto-KDTAVP3R.jpg
> I changed the spring without any problems. It's easy to do.
> The size of the spring isn't really that critical, mine comes from a
> friends "collection".
> You might find one a regular hardware shop.
> I made a photoshoot of the whole operation.
> Just let me know if you need more details.
>
> Best Regards,
> Eric
> (the Netherlands)


--
Stefan Murry

[SteveB[_2_]]

Pulling the bags and taking the valve apart is not a problem. Getting
the valve to not leak is the problem.
Changing the valve system was one of the changes from DG-200 to
DG-202. The bike brake cable system can't generate enough force
to really close the valve. I can get the valve to not leak except
when it's in the wing.
The one trick I used putting the valve back in was to put a drop of
silicone sealant into the head of the allen screw that holds the valve
in
place, put the allen/hex wrench into the screw and let it dry. Yes
you will need 6(?) 4mm hex wrenches. If you drop a screw while
putting the valve back in
the only way to find the screw is to take the valve out again.
Someday I want to fly my -200 with water.

Steve

On Dec 3, 11:23*am, "S. Murry" > wrote:
> Eric,
>
> Thanks for responding. *Unfortunately, my system appears to be different.

[Marc]

On Dec 3, 9:03*am, "S. Murry" > wrote:
> Thanks, Marc.
>
> I don't think 1500+ dollars for the rebuild kit is in the cards (1000
> euros for the "service contract" + a couple hundred for the rebuild kit,
> with shipping). *So, wish me luck as I dig in myself...

Actually, the kit cost me all of US$85 including shipping just 5 years
ago. I've owned three DGs over the years, including one ordered new.
No more, thanks to the service contract lunacy...

Marc

[S. Murry]

Marc,

I guess it's comforting to know that if I had paid the ridiculous service
fee that the valve rebuild kit is at least reasonably priced :).

Seems like DG ought to be able to make enough profit of an $85 O-ring +
spring kit to make it worthwhile to sell it without the service contract,
but I guess that's a topic that's been well covered here already. In the
meantime, Home Depot here I come...

--Stefan


On Sat, 03 Dec 2011 22:14:49 -0600, Marc > wrote:

> On Dec 3, 9:03 am, "S. Murry" > wrote:
>> Thanks, Marc.
>>
>> I don't think 1500+ dollars for the rebuild kit is in the cards (1000
>> euros for the "service contract" + a couple hundred for the rebuild kit,
>> with shipping). So, wish me luck as I dig in myself...
>
> Actually, the kit cost me all of US$85 including shipping just 5 years
> ago. I've owned three DGs over the years, including one ordered new.
> No more, thanks to the service contract lunacy...
>
> Marc


--
Stefan Murry

[[email protected]]

Hi Eric

Can I trouble you for a copy of your DG200 water ballast repair photos/video please? The link appears not to work now.

It appears the valve in my right wing does not return to the closed position so I'd really appreciate some guidance material.

Many thanks

Mick

[Chris Snyder]

I have an uninstalled water ballast system that came with my DG-200. I could ask DG for installation instructions as I do hope to one day add the system back (mine was removed). I'm happy to take pictures of the valves and such if you need them. I'd appreciate pictures of your installation too as even the holes have been removed so I haven't a clue what the installation looks like. I can post all of the information in a blog post so it's available to everyone.

Do you want to contact me at Soaring Virginia at Gmail?

Chris Snyder
Merlin Soaring


On Thursday, August 23, 2018 at 3:24:08 PM UTC-4, wrote:
> Hi Eric
>
> Can I trouble you for a copy of your DG200 water ballast repair photos/video please? The link appears not to work now.
>
> It appears the valve in my right wing does not return to the closed position so I'd really appreciate some guidance material.
>
> Many thanks
>
> Mick

[DG300PI]

Op vrijdag 24 augustus 2018 17:35:42 UTC+2 schreef Chris Snyder:
> I have an uninstalled water ballast system that came with my DG-200. I could ask DG for installation instructions as I do hope to one day add the system back (mine was removed). I'm happy to take pictures of the valves and such if you need them. I'd appreciate pictures of your installation too as even the holes have been removed so I haven't a clue what the installation looks like. I can post all of the information in a blog post so it's available to everyone.
>
> Do you want to contact me at Soaring Virginia at Gmail?
>
> Chris Snyder
> Merlin Soaring
>
>
> On Thursday, August 23, 2018 at 3:24:08 PM UTC-4, wrote:
> > Hi Eric
> >
> > Can I trouble you for a copy of your DG200 water ballast repair photos/video please? The link appears not to work now.
> >
> > It appears the valve in my right wing does not return to the closed position so I'd really appreciate some guidance material.
> >
> > Many thanks
> >
> > Mick

here's a new link: https://photos.app.goo.gl/1yYmqgg3oauFT2bu7

Best, Eric