Jul 19, 2021     First Engine Start       Category: Engine

First engine start today a success. Had to replace starter solenoid and charge battery overnight, but otherwise it fired up after just a few revolutions. Engine data attached with and without cowlings on. One issue with EGT #4 and have replacement sensor on order. No leaks observed. Minor smoke from under cowling, probably just surface oil burning off. Added additional 1-1/2 its oil.

  Jul 17, 2021     Day Before First Engine Start - (3 hours)       Category: Engine

Developed a start-up checklist.

Filled up a 5gal fuel can with Avgas. Disconnected fuel line before fuel controller and purged right and left fuel lines with electric fuel pump. Confirmed flowmeter working. Found minor leak at bulkhead fitting.

Added additional oil to sump. Measuring just under 8 qts.

Fabricated CAN jumper from SteinAir parts and installed on right wing harness. Everything seems ready for initial engine run tomorrow.

  Jul 16, 2021     Engine Pre-Oil; Firing Order Check; Brake Fluid Charging - (4 hours) Category: Engine

Added approx 2 qt of oil about to engine using fabricated PVC tank over about an hour. Pulled top plugs and manually turned prop to pump oil through engine and accessories. Tied battery to main bus and turned engine over with starter to circulate oil. Pressure increased to 50 psig. Reading 6 quarts in sump.

Confirmed cylinder firing order 1-3-2-4 by removing all spark plugs, reconnecting to leads, and grounding to the engine case. Ungrounded p-mags and slowly turned prop and observed plugs sparking in the correct order.

Charged brake fluid to master cylinder and purged brake lines.

Received interior from Classic Aero today. Unboxed and checked inventory. Called to get installation instructions.

  Jul 15, 2021     First Electrical Power-Up Category: Engine

Confirmed both p-Mags have jumpers between terminals 2 and 3. Realigned the cooling tubes to focus air on the fins.

Fabricated new seat hinges and installed on floor. Installed seat backs.

Tied the battery. When switching to BATT on panel, smelled burning, so immediately turned off. I suspected it's coming from CB panel touching side of housing. Untied battery and installed plastic edging along right side along bus bar. Re-tied battery and this solved the problem. PFD, MFD, G5, and rocker switches all lit up. Confirmed correct operation and display on PFD for canopy latch. Confirmed fuel pump and flap motor control from panel. Confirmed GTN650 powers up. Confirmed light dimmer switches work. Confirmed operation of the defrost fan from the panel. The LED does not function.

Went through the procedure for timing the p-mags. Removed Cyl #1 spark-plug and turned the prop CW until at TC and confirmed this aligns with TC mark on rear of flywheel at engine centerline. Rotated prop CW 2 teeth (~4 deg after TC). With p-mag OFF, set BATT and observed red lights one each p-mag. Disconnected MAP line to sensor and blew into line until red light flashed. Blew a second time until light flashed green. Cycled battery OFF/ON and LED was solid green on both p-mags. Turned prop slightly to confirm light turned from red to green to red as prop passed through TC. Couldn't be easier.

  Apr 24, 2021     Engine Systems: Electrical - (5 hours)       Category: Engine

Completed FWF wiring including mounting the avionics relay on the aft FW and shunt on the forward FW. Connected alternator to shunt and then to master solenoid on side connecting master and starter solenoids. What remains is running power to A/C compressor and grounding all wires to FW.

  Apr 23, 2021     Engine Systems: Electrical - (4 hours) Category: Engine

Continued connecting wiring including oil and fuel pressure sensors, manifold pressure, and oil temp. Connected master and starter field wires. Ordered 8 ga wire from AS to complete alternator shunt install. Also ordered 16 ga wire for a/c compressor clutch field power.

  Apr 23, 2021     Engine Systems: Sensors - (4 hours) Category: Engine

Completed connecting EGT and CHT sensors to leads using overlap connectors. Covered connectors and wiring with shrink wrap and used safety wire to secure mesh sleeves. Confirmed continuity of each sensor.

  Apr 21, 2021     Engine Systems: Sensors - (2 hours)       Category: Engine

Connected manifold pressure ports on P-mags to manifold pressure sensor using modified fittings. Secured manifold pressure sensor with additional adel clamp. Connected oil pressure sensor with Molex connector. Routed ground wire behind brake fluid reservoir to keep out of way.

What I did was replace the F-4 DTX-S on the Garmin firewall-mounted transducer with a 4-MTX-3 tee and 4-G6X-S adapter to 1/4" NPT where I connected a 90 deg 1/4" pneumatic swivel fitting. I ran 1/4" tubing to an insert tee then ran the rubber tubing supplied by E-Mag to each p-mag with the supplied pulse dampener in each line. On the RV-14A, the manifold pressure is taken off the #3 cylinder with a braided hose supplied by Vans which connects to the other side of the 4-MTX-3 tee.

  Apr 20, 2021     Engine Systems: Air Conditioning - (2 hours) Category: Engine

Began modifying left side baffling to accommodate a/c compressor. Will have to get creative with this. Decided it makes sense to start on cowling to better see how the baffling needs to be modified to ensure air flow over top of cylinders on that side. First the prop needs to be installed. Fitted spinner backplate to hub and positioned prop to prepare to lift it with shop hoist. Reversed the bracket side arms to original orientation.

Discussed a/c install with John. He will send alternate belt that is wider for better traction in compressor pully. Need to remove paint on bracket to ensure good ground to engine. He will send fan switch and relay.

  Apr 20, 2021     Engine Systems: Air Conditioning - (2 hours)       Category: Engine

Measured for v-belt using rope. Calculated outside circumference using equation C2=C1+ 2pi(belt thickness) as reasonable estimate for effective length. Purchase 40" Dayco top cog belt (15400) and mounted compressor to check alignment. It's not bad, but any forward adjustment will not be possible without modification to bracket. Discharge and suction are oriented upward so best hose routing will be across top of cylinders, but don't see an issue here. Manual states these need to be oriented upward no greater than 45deg from vertical, so downward installation is not permissible. Probable good to fire sleeve these. Tension adjustment arm needs to come forward so additional washers and longer bolts required. Otherwise, there's sufficient separation from #2 cylinder, oil return line, and starter, actually a very nice fit.

  Apr 18, 2021     Engine Systems: Air Conditioning - (1 hour)       Category: Engine

Unpacked compressor (Valeo 103-52070) and test fit onto mounting plate to check alignment with the forward dual pulley. Removed baffle sections of left side. Was able to move into better alignment by repositioning bracket side arms with the compressor fully forward on the bracket. The alignment is close but it's at the fully forward limit. The only other possibilities would be to elongate the bracket mounting holes, not simple to do in steel, or reduce the thickness of the forward bracket side arm. Ordered Lycoming studs from AS based on what's required on the IO-390-C which uses the same mount for a compressor bracket.

  Apr 17, 2021     Engine Systems: Controls - (4 hours)       Category: Engine

Installed new turnbuckles from Don and connected mixture and throttle controls. Ordered parts from AS. Installed Thermo Tec clamp-on heat shield between exhaust and controls. Ordered second one. Connected EGT2 to thermocouple wire using overlap clamp to see how well that works. Waiting on more to arrive. Connected fuel flow transmitter with Molex.

  Apr 16, 2021     Engine Systems: P-Mags - (6 hours)       Category: Engine

Wired p-mags starting from left side to include tach pick-up and ground. Ran and secured plug wires per Lycoming instructions, Left: 2T/4T/1B/3B; Right 1T/3T/2B/4B.

  Apr 15, 2021     Engine Systems: Exhaust - (2 hours)       Category: Engine

Replaced exhaust pipe gaskets with copper #77611 gaskets and torqued to 190 in-lbs.

  Apr 13, 2021     Engine Systems: Controls - (4 hours)       Category: Engine

Installed bracket and routed control cables using prop cable in place of alt air cable not yet arrived. Confirmed with Don Rivera that phenolic spacer not required for FM-200 and ordered links and rod ends. Ordered custom push-button control cable from ACS for alternate air. Ordered exhaust pipe shield https://www.thermotec.com/products/clamp-on-heat-shield . Ordered inlet transition https://www.merlinmotorsport.co.uk/p/aluminium-air-inlet-polished-ai?pn=15767 . Installed and secured prop cable to governor. Installed control bracket under panel.

  Apr 11, 2021     Engine Systems: Controls - (2 hours)       Category: Engine

Mocked up options for controls and think I found the best option. Will need to order a few parts.

  Apr 10, 2021     Engine Systems: Controls - (2 hours)       Category: Engine

Build a stand to evaluate best configuration for installing mixture, throttle, and alternate air cables.

  Apr 09, 2021     Engine Systems: Baffling - (5 hours)       Category: Engine

Continued working on installing baffle except for left side until compressor and bracket arrive.

  Apr 08, 2021     Engine System: Air Induction       Category: Engine

The FM-200 alternate air duct and filter arrived from Airflow Performance.

  Mar 30, 2021     Engine Systems: Baffling - (8 hours)       Category: Engine

Started installing baffling.

  Mar 29, 2021     Engine Systems: Oil Cooler - (3 hours)       Category: Engine

Primed and installed oil cooler bracket and cooler and will complete vent assembly when back-ordered parts arrive.

  Mar 27, 2021     Engine Systems: Heat muffs and scat ducting - (2 hours)       Category: Engine

Finished installing scat ducting between heat muffs and to vent flanges on firewall.

  Mar 26, 2021     Engine Systems: Fuel xpdr and heat muffs - (2 hours)       Category: Engine

Modified Vans red cube install to move further away from exhaust pipes and mount on hose rather than cube. Was able to use existing hose to connect to FM200A inlet.

Made heater muffs using alternate end caps purchased from Rick and Robin Wings. They fit snug to exhaust pipes and are eccentric to permit more position flexibility. They replaced Vans parts that are known to prematurely wear out and potentially damage the exhaust. Realized I had to relocate my quick drain oil valve to the left side due to interference with the connecting scat hose. Drain oil sump, moved valve, and recharged with same oil.

  Mar 25, 2021     Engine Systems: Fuel and Oil Category: Engine

Installed fuel line from firewall to fuel pump inlet after reinstalling bulkhead fitting removed to enable installation of exhaust pipe.

Removed cover over induction air port and temporarily fit FM-200A. Discussed install with Kyle at Airflow Performance and ordered their throttle/mixture bracket that mounts under the oil sump, a cleaner design than that provided by Van's. Rotating the FM-200 to place the control arms below the sump will move the fuel inlet and outlet fitting and require new hoses.

Measured and ordered a new AN4 outlet hose with integrated fire sleeve to fuel divider from Aircraft Specialty Products.

Also ordered cable bracket, alt air tee and filter for test fitting to FM-200A. Reached out to James Aviation for advice/support on cowl modifications. Also to Bauer Aviation for info on his airbox if I decide to use filtered ram air. Ordered extra cable bracket for alt air control and researched push/pull cable to mate with linkage.

Spoke with John and he is shipping ac compressor and bracket. This all should give me all I need to assess required cowl modifications.

  Mar 24, 2021     Engine Systems: Exhaust       Category: Engine

Completed installation of EGT and CHT probes.

Identified and temporarily routed all FWF wiring.

  Mar 23, 2021     Engine Systems: Exhaust - (6 hours)       Category: Engine

Finished main exhaust install, but waiting on head muff end caps from Rick to complete. Installed support from engine case. Included directions were a bit confusing. Installed heat deflectors. Began installing EGT probes.

  Mar 22, 2021     Engine Systems - (6 hours)       Category: Engine

Installed alternator and power cable. Measured for new v-belt required for smaller dual pulley. Had long chat with John about A/C and followed up with emails on compressor bracket and hose fittings. Requested he send main components to begin install. Started exhaust system install.

  Mar 20, 2021     Engine Install - (4 hours)       Category: Engine

Big day....installed the engine with help from a couple of pilot neighbors. Took about an hour with only a little difficulty. Installed red cube, clamps, and cables to starter.

  Mar 18, 2021     Engine Prep - Oil Fill - (2 hours) Category: Engine

Installed Saf-Air drain valve on right side drain. Installed four new spark plugs to match four existing. Confirmed gap at 0.030. Charged 6 quarts of AeroShell 80.

  Mar 16, 2021     Engine Prep - Uninhibiting Engine - (4 hours)       Category: Engine

Removed all lower spark plugs and temporary plastic plugs. Inserted 5/8" plastic tubing to each and routed to trash can. Turned engine over four times by hand and observed oil flowing out of #1 and #2 cylinders only. Drained perhaps 1/2 qt of oil from sump by removed both oil drain plugs. Moved engine on hoist to prepare for mounting.

  Mar 15, 2021     Various Engine Items - (4 hours) Category: Engine

Installed boots ordered from AS onto master/starter relay. Ordered Saf-Air P5000 oil drain valve and spare o-rings from AS to be installed prior to first fill. Spend some time researching a/c hose crimpers. Realized installed hoses are reduced barrier type which require corresponding die. All affordable beadlock hose crimpers made in China. Decided on Mastercool copycat unit which comes with needed dies and a separate hydraulic pump to better allow field crimping. A few day earlier ordered bulkhead a/c fittings and 90 deg hose ends from Summit Racing.

Reviewed options for induction air from Airflow Performance manual which avoids installing fiberglass plenum where a/c compressor will ultimately mount. Best option seems to be the alternate air duct and filter https://airflowperformance.com/index.php/product/fm-200-alternate-air-duct-2-valve/ as shown in Appendix C of installation manual https://airflowperformance.com/wp-content/uploads/2018/12/API-Installation-Service-Manual-9003.pdf. I will need to determine the best way to feed cool outside air into the filter, possibly using a cowl air scoop. https://shop.vansaircraft.com/cgi-bin/shop.cgi?ident=1615895417-102-633&browse=engines&product=cowl-airscoop

The two COM antennas and LOC/GS/VOR antenna arrived today.

Picked up two 4" 1/2X20 bolts to thread into prop flange and 3' 1/2" black iron pipe from Lowes to assist in turning over crankshaft in preparation for discharging preservation oil. Gave a bit of thought on how to best do this, reading all relevant Lycoming service docs. These recommend tiling engine to each side to aid in draining oil which can only be done while on hoist and before installation. Purchased hose to place in lower spark plug holes to aid in directing oil away from cylinders if needed. Plan to bag each cylinders head to reduce the mess. Waiting on spark plugs (Denso IKH27) to arrive.

  Mar 13, 2021     Engine Prep - (4 hours)       Category: Engine

Borrowed engine hoist and with Carlos' help lifted engine off pallet onto workbench. Installed prop governor. Installed second p-mag.

  Mar 11, 2021     Installing Rear Fittings - (3 hours)       Category: Engine

Installed fitting on rear of engine as described in plans.,

  Feb 09, 2020     Engine Delivery Update Category: Engine

Got an update from Vans that my approximate ship date for the IO390 is 9/22/20....so most likely I will see the engine in Oct. That's 9 months away!

  Nov 08, 2019     Lycoming Engine School: Day 5 - (6.0 hours) Category: Engine

Class review of fuel injection, magnetos, etc. Completed magneto timing in shop.

  Nov 08, 2019     Lycoming Engine School: Day 5 - (6.0 hours)       Category: Engine

Class review of fuel injection, magnetos, etc. Completed magneto timing in shop.

  Nov 07, 2019     Engine: Lycoming School Day 4 - (7 hours)       Category: Engine

Reviewed in class engine maintenance and troubleshooting topics. Reinstalled cylinders and valve train in lab.

  Nov 06, 2019     Engine: Lycoming School Day 3 - (7 hours) Category: Engine

Tour of Lycoming factory

  Nov 05, 2019     Engine: Lycoming School Day 2 - (7 hours)       Category: Engine

Reviewed crankshaft and camshaft design and servicing. Reinstalled both and reassembled case.

  Nov 04, 2019     Engine: Lycoming School Day 1 - (7 hours)       Category: Engine

Day 1. Reviewed Lycoming service documentation sources, definitions, and history. Worked in group to fully disassemble O360 engine. Class held at Pennsylvania College of Technology, Montoursville, PA