Project: CH750-SR   -  
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Builder Name:Skip Rhudy   -  
Project:   Zenair - CH 750   -   VIEW REPORTS
Total Hours:551
Total Flight Time:
Total Expense:N/A
Start/Last Date:Sep 17, 2019 - No Finish Date
Engine:Corvair
Propeller:Sensenich W642KL-35GS
 
Friendly URL: https://eaabuilderslog.org?s=CH750-SR

Home or Last Project Picture

Mar 14, 2021     Engine on Test Stand - (8 hours)       Category: Engine
At William Wynne's hangar, supervised top-end build and test run. Finished installing: Oil pan, starter bracket / ground bar, starter. Filled with oil. Put on test stand and rotated prop for 30 minutes by hand while running oil pump with drill adapter. Installed distributor at correct test run position.

Test run commenced about 300pm. Engine started within 2 seconds. Ran at varying RPM for 30 minutes.

Adjusted heavy duty oil pump bottom plate to account for slightly stiff rotation to bring it into a level of resistance to rotation that is consistent with other engine builds. Removed from test stand and prepped engine for transport back to Texas.

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Mar 13, 2021     Top End / Accessory Attachment - (9 hours)       Category: Engine
Assembled top end of motor at William Wynne's hangar as supervised build. These components assembled as per specification in the SPA Corvair Engine Assembly Manual except when William recommended and showed newer, improved methods.

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Feb 27, 2021     Final engine assembly prep - (2 hours)       Category: Engine
Ensure all tools and materials per the final assembly list in the SPA Corvair Engine Assembly Manual and per William Wynne's required tools and materials list put together and made ready to transport to Green Cove Springs, Florida.

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Oct 21, 2020     Harmonic Balancer Final Install - (.5 hour)       Category: Engine
Note to self: Write SPA a note about their install documentation. 2 inch install bolt does not penetrate far enough into crankshaft to tighten balancer down correctly (at least on my crankshaft). Stripped two inch bolt.

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Sep 27, 2020     Piston / Cylinder Install Prep - (1 hour)       Category: Engine

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Sep 22, 2020     Piston / Cylinder Install Prep - (1 hour)       Category: Engine

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Jun 27, 2020     Painting Cylinders and Studs - (1.5 hours)       Category: Engine
Painted some cylinders and painted also the head studs. Head studs can tend to rust so I just painted them over flat black. Same with cylinders, they are prone to rust without paint. High temp engine paint with ceramic -- 500 degree. Note ingenious paint fixture, credit to Billy Kerchner who is building a Corvair powered Sonex (see his posts on WW FlyCorvair facebook group).

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Jun 26, 2020     Cylinder cleaning - (2 hours)       Category: Engine
Finished control arm / clevis opening with filing. Then, change of pace: Working on prepping my 3.0L cylinders for installation on my short block Corvair. This is preparation for painting. Was concerned about the step area along the cylinder skirt and asked William Wynne about it. The gasket in that area is RTV green, about a 1/16 bead. No worries there. The areas near the step that are machined out near the stud channels are there so the cylinder does not vibrate against the stud in operation.

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Jun 10, 2020     Parts from Green Cove Springs - (.5 hour)       Category: Engine
Received various engine parts for Corvair powerplant.

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May 28, 2020     Cylinder Assembly Research - (1 hour)       Category: Engine
Cylinder assembly reading, SPA manual pp124 to pp143

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May 13, 2020     Assembly Research - (1 hour)       Category: Engine
Studied cylinder assembly procedure. pp103 to pp 124

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May 11, 2020     Corvair 3.0L Cylinder Set - (.5 hour)       Category: Engine
Ordered 3.0L Corvair Cylinder Set for TZero

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Apr 07, 2020     Corvair 110HP head overhaul - (.5 hour)       Category: Engine
Ordered 110HP head overhaul from Sport Performance Aviation.

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Mar 26, 2020     ACF-50 Crankshaft - (.5 hour)       Category: Engine
To protect the crankshaft while waiting further build out I slathered on ACF-50 and got it in the journal areas too.

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Mar 25, 2020     110 HP Head Search - (2 hours) Category: Engine
Found a possible source for 110 Head. Contacted Mike's Corvair Parts. Since I have one head at William's hanger, casting #3856759, Mike is going to look to see if he has one around his main store.
 
Feb 24, 2020     Short Block - (1 hour)       Category: Engine
Drive from Green Cove Springs Florida to Seguin Texas. 16 hours starting Sunday at 130pm arriving Seguin Monday about 11am. Move TZero into shop.

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Feb 23, 2020     Short Block - (3 hours)       Category: Engine
Rear oil housing install. Oil pickup install. Gold top and gold oil pan.

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Feb 22, 2020     Short Block - (12 hours)       Category: Engine
Installed oil gallery plugs. Put TZero in engine build stand. Put in crankshaft, camshaft, and aligned them. Lubed the cam lobes. Closed the case and torqued correctly. Put on 5th bearing case. Drilled and pinned 5th bearing. Put on gasket material and torqued 5th bearing housing correctly. Put on 5th bearing oil seal. Installed safety shaft and prop studs.

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Feb 21, 2020     Case Inspection - (3 hours)       Category: Engine
At William Wynne's hangar inspected TZero case for cleanliness. Restored all threads. William removed a case dowl pin from an older case because processing at SPA had lost the dowel pin in mine. Noted my original case bolts / nuts not returned. Other bolts instead.

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Jan 12, 2020     Engine Cleaning - (1.7 hours) Category: Engine
More tube, hardware, and valve cover cleaning.
 
Jan 10, 2020     Engine Cleaning - (3.6 hours)       Category: Engine
Cleaned all kinds of parts including pushrod tubes, head clamps, clamp bolts, baffles, baffle hardware, valve cover. Some pushrod tubes may not be useable because of internal pitting which I don't approve of and find not acceptable. Plan to have William Wynne review.

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Jan 10, 2020     Engine Shipping - (2 hours)       Category: Engine
Crated and shipped engine case to Sport Performance Aviation LLC to have it bored to be a 3.0L engine.

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Jan 09, 2020     Engine Cleanup - (1 hour) Category: Engine
Cleaned up case bolts and nuts to fasten case together to ship to Sport Performance Aviation LLC.
 
Jan 08, 2020     Engine Parts - (2 hours) Category: Engine
Ordered following components for rebuild from Sport Performance Aviation: Case bore service, case cleaning service, 5th Bearing Crankshaft Service w/New gear, crank core charge (refundable), 5th Bearing Journal - 2nd Gen, 5th Bearing Housing Kit, CV1100 Cam and Lifters, CV200-HV Rear Assembly, CV3301 - E/P distributor, Gold Billet oil pan, Oil pan installation kit, Starter kit
 
Dec 31, 2019     Engine Cleaning - (1.2 hours)       Category: Engine
Clean head attachment hardware. Inspect rocker arms. Not considered useable according to William Wynne's specs. Will have to find replacement. ACF-50 all head attachment components, useable or unuseable. Threw away pushrods.

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Dec 30, 2019     Engine Cleaning - (.9 hour)       Category: Engine
Clean 6 pushrod tubes.

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Dec 29, 2019     Engine Cleaning - (3.5 hours)       Category: Engine
Removed gasket material from rear oil case housing. Wire brushed oil pump housing bolts and cover plate. Cleaned oil pump gears.

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Dec 14, 2019     Engine Cleaning - (3 hours)       Category: Engine
Finished cleaning left case and prep for sending to Florida. Began cleaning heads. Evaluation of head quality. Pictures sent to FlyWithSPA / FlyCorvair for a review. Two cylinders may be too damaged for reconditioning.

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Dec 12, 2019     Engine Cleaning - (2 hours) Category: Engine
Remove rust and scale from case studs.
 
Dec 09, 2019     Engine Cleaning - (1.5 hours) Category: Engine
Engine internal, external, and lifter bores. Also a few more screw holes in base of case half. Removed gasket material. Ready to clean the case studs.
 
Dec 08, 2019     Engine Case Cleaning - (2 hours)       Category: Engine
Left case cleaning. External. Internal. Oil galleries and all screw / dowl holes. Flush oil passageways. Remove scum and varnish.

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Dec 06, 2019     Case / Cam - (1.5 hours)       Category: Engine
Left case half cleaning. Exterior and interior. Oil galleries. Lifter bores. Clean cam, treat with ACF-50, wrap in plastic, ready to take to Florida.

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Nov 29, 2019     Engine cleaning - (3 hours)       Category: Engine
Finished cleaning right case half. Removed rust / scale from case studs. Cleaned stud threads. Treated all studs with ACF-50 and wrapped in plastic for temp storage before taking to Floriday. Cleaned but camshaft and cam gear. Restored rear oil case attachment hardware to near orginal condition. Restored old head nuts (but will not reuse due to minor munging). All treated with ACF-50 and stored.

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Nov 24, 2019     Engine crankshaft - (2 hours)       Category: Engine
Finished cleaning engine crankshaft. All passages flushed with solvent. Main bearing and connecting rod throw journals cleaned with light application of scotch brite 7447. Slathered in ACF-50 and wrapped for storage until delivery to Florida for processing into flight engine crankshaft.

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Nov 22, 2019     Engine Case and Crankshaft - (2 hours)       Category: Engine
Almost finished cleaning R(ight) case half. All holes cleaned. Oil gallery cleaned. Surfaces cleaned and dowl holes cleaned. Still needs to have studs de-rusted / de-scaled. Minor pitting on some gasket surface areas that is not significant. No pitting on case mating surface. Internal surfaces clean enough for assembly.

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Nov 17, 2019     Case and Crankshaft cleaning - (1.8 hours)       Category: Engine
Gasket removal. Discovered that gasket remover does a great job of getting stubborn varnish out of internal areas that are hard to get at. Crankshaft cleaning / minor polishing. Flushed all the crankcase oil passages thoroughly with solvent. Note that in first crankshaft pic the first two throws have very mild surface corrosion. In second picture it is gone -- just a bit of light rubbing with Scotch-Brite 7447.

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Nov 15, 2019     Case cleaning - (1 hour) Category: Engine
Case detailing, removing dirt on outside, varnish on inside. Removed oil gallery plug for later cleaning.
 
Nov 09, 2019     Detail cleaning - (2.5 hours)       Category: Engine
Parts cleaner / lots of Scotch-Brite 7447

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Nov 02, 2019     Case Cleaning / Crankshaft inspection - (2 hours)       Category: Engine
More case cleaning. Crankshaft inspection and attempt removal of woodruff key. Wouldn't come out. Taking to William Wynne / Dan Weseman.

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Oct 28, 2019     Engine Cleaning - (2 hours)       Category: Engine
Cleaning case halves.

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Oct 21, 2019     Engine Core Teardown - (4.5 hours)       Category: Engine
Remove stuck cylinders by whatever means necessary without damaging case. Result: Success. Crank looks serviceable as well as heads, case, and the oil routing end case.

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Oct 17, 2019     Engine Core Teardown - (2.5 hours)       Category: Engine
Remove front of case / bell housing. Split case by unding case bolts. Remove cylinder 5 by pounding on underside of piston stuck in cylinder. Same technique pounded piston out of cylinder 3. William Wynne recommended cutting slots (weak spots) on interior of cylinder wall to help break cylinder out of case.

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Oct 11, 2019     Engine Core Teardown - (3 hours)       Category: Engine
Remove fan housing. Unable to get crank to rotate, so had to cut through rods (recommended by William Wynne). Cut through rods to be able to remove cylinders. After cutting through 4, began to be able to rotate crank while cylinders 1 & 2 still attached by rod. Undid rod bolts. Unable to remove rod cap. Sawed through both remaining rods. Tapped rod bolts out using previously removed rod with bolts set on the rod bolts not coming off and tapping lightly.

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Oct 07, 2019     Engine Core Teardown - (2.5 hours)       Category: Engine
Remove pushrod tubes and pushrods. Remove head stud bolts and rocker retainers. Remove cylinder bottom cooling baffle. Remove cylinder heads.

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Sep 25, 2019     Engine Core Teardown - (1.5 hours)       Category: Engine
Remove exhaust logs, engine cooling baffles (end pieces). Remove harmonic balancer. Remove distributor retaining screws. Left distributor in until understanding if it can be just pulled out. Videos can be found here: https://corvair750.blogspot.com/2019/09/steady-progress.html

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Sep 18, 2019     Engine Core Teardown - (1.5 hours)       Category: Engine
Began tearing down core engine for flight engine conversion rebuild. Engine serial No: T04I3RG, Heads S/N: 3856743. This identifies as a 1965-1969 95 HP Corvair engine core.

Power washed. Removed sheet metal and accessories including carburetor and some vacuum lines.

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