Mar 07, 2020     Clamps for Secondary Ignition Wires - (1.5 hours) Category: Engine

Explored ways of mounting spark plug wires from port side secondary ignition to coil on firewall. Used doubled 5/8" cushion clamps to hold wired together. Mount doubled clamp set to clamp on frame member.

  Feb 29, 2020     Mixture Control Arm Clamp - (0.6 hour)       Category: Engine

Changed out barrel wire clamp on the AeroInjector that was binding the pivot action on the arm. Operation works well on the simple solid wire Bowden cable. Will likely change the 5.5 foot cable with a A-790 VERNIER CONTROL with a red knob.

  Feb 23, 2020     Mixture Control Cable - (1.5 hours)       Category: Engine

Opened FW hole to install aluminum pass-through bushing. Loose control slide with mixture control arm on AeroInjector will need upgraded to a mixture cable with a vernier.
Explored locations for firewall terminal block.

  Feb 22, 2020     Mixture Control Cable - (3 hours)       Category: Engine

Removed slave throttle control.
Locate and drill firewall pass-through for mixture cable. Connected cable to AeroInjector. Securing cable in clamp binds against the control arm resulting in poor control from the simple solid cable.
Added final 12 CCP-42 rivets to glare screen attach angle.

  Jul 13, 2019     Makeup new oil lines - (3.5 hours) Category: Engine

Made new oil lines to route from engine to oil filter and oil filter to turbocharger using braded AN4 hose and Aeroquip fittings. Secured lines to engine mount tubes with cushion clamps.

  Jul 13, 2019     Attach Oil pressure Gauge Tap - (0.3 hour) Category: Engine

Removed VDO oil pressure sensor and attached HF oil pressure gauge port from adapter provided with Harbor Freight gauge kit.

  Jun 22, 2019     Turbo cooling plumbing - (1.5 hours) Category: Engine

Adjust turbo cooling circuit hose lengths to fit. Shortened 5/8" hose and added 18" of 1/2" to provide a smooth bend radius to radiator.
Using Oeticker clamps for more permanent connections, hose clamps for removable connections.

  Jun 15, 2019     EGT sensors - (1.5 hours) Category: Engine

Drilled 3 holes in exhaust pipe 4" from manifold flange, starting with #40 pilot to 3/16" with an ending hole diameter of 13/64". Started exhaust wrap on port-side exhaust.

  Jun 10, 2019     Low oil level mark - (1.5 hours) Category: Engine

Added 2 qts of 20-50 Brad Penn oil, rolled the fuselage to the runway, waited ten minutes then marked the low oil level on the dipstick with the edge of a small triangular file.
Removed flaking engine paint from the top of the block (I regret painting the magnesium block!).

  Jun 08, 2019     Turbo Exhaust Flange - (1.5 hours) Category: Engine

Cut six threads from 1-1/4" turbocharger exhaust flange mounting bolts, and stud. Filed ends and polished on Scotchbrite wheel. Installed graphite gasket and checked clearance of lengthened exhast pipe. Weld extenton on tubo exhaust pipe and extension is clear of motor mount frame.

  Jun 08, 2019     Secure oil lines - (1 hour) Category: Engine

Tightened oil line penetrating starboard side engine flange, secured fittings to external oil filter. Checked fitting turbocharger extended sump, however the size of the sump interfered with the wastegate actuator mounting. Reinstalled the standard oil flange fitting and gasket.

  Jun 02, 2019     Install turbo oil gasket - (0.4 hour) Category: Engine

Installed standard turbo oil port with AN6 fitting to turbocharger body with a purchased Garrett T-25 gasket. Purchased this: https://www.ebay.com/itm/Turbo-Oil-Return-Drain-Gasket-Set-For-Garrett-T25-T28-44mm-hole-to-hole-5PACK/292347309985?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

  May 04, 2019     CHT & oil pressure wiring - (0.5 hour) Category: Engine

Add VDO oil pressure sensor wire. Drilled exit hole for snap bushing to pass CHT and oil pressure wiring.

  May 04, 2019     Attach oil cooler baffling - (2.5 hours) Category: Engine

Drill, deburr, rivet oil cooler baffle to port side rear baffle. Added #6 nutplates to attach starboard side rear baffle.

  Apr 21, 2019     Oil Cooler Baffling - (3.0 hours) Category: Engine

Used thin cardboard sections to layout templates for baffling around engine oil cooler. Middle section angle cuts to match top deck of engine block. Port and starboard pieces located step from VW engine deck to mounting flange step. Templates aligned together and traced on to a sheet of 0.025" 6061-T6.
Drilled relief holes for inside corner cuts. Used shears to cutout engine contour in Al sheet. Sanded and fiiled contour on bottom of baffle section across the oil cooler. Once the seal across the bottom didn't show an air gap, the starboard side was bent 90 degrees and the bottom and vertical step were filed to provide a similar light-tight seal.
Riveted a short angle to the starboard rear corner. Will set two #6 nutplates to engage the rear baffle.

  Apr 21, 2019     Cutout cooling air doorway in baffle - (1.3 hours) Category: Engine

Layout for oil cooler air flow opening. Drilled corner holes and one in center for sheetmetal nibbler. Used nibble to remove the middle of the ductwork. Filed to match layout marks.

  Apr 13, 2019     Turbo Radiator Mounting Bracket - (1.5 hours) Category: Engine

Fabricated a short mounting bracket to brace the turbocharger radiator against an engine mount tube. Incorrectly fabricated the first bracket with two nutplates. Second attempt used a single #10 nutplate for mounting to a cushion clamp, with the #8 nutplate attached to the radiator plenum securing it to the bracket.
The arrangement provides a three-point mount for the radiator.
Cut several pieces of rubber tubing to connect the pump and radiator.

  Mar 30, 2019     Remove Center Flashing Between Cylinders - (0.8 hour) Category: Engine

As demonstrated by Bob Mica at Jeff Schultz' Firewall Forward seminar in Lee's Summit, used a 3/16" drill bit to open up the area on the AeroVee's cylinder head in the central area between cylinders. The starboard head had a small space, however the port side was completely closed off by casting flash. Drilled a series of increasingly larger holes in the area trying to overlap holes, using the side of the bit to 'mill' between holes. Used a medium thickness flat file to smooth sharp area between holes. Drill chuck marred the ends of the cooling fins adjacent to the central space.

  Mar 30, 2019     Port rear baffle fitup - (0.8 hour) Category: Engine

Removed the port-side rear baffle. Upsized the engine vent passthrough to 1" for fitting a 5/8" ID grommet. Fit the baffle to 'tuck' the tab into the engine SuperTin as discussed during Jeff Schultz' Firewall Forward seminar in Fall 2018. The backend of the baffle now looks to seal well, and appears to minimize areas of leakage.

  Mar 30, 2019     Fit Turbocharger Intake - (0.5 hour) Category: Engine

Have struggled with fitting the 2" 45 deg silicone intake tube to the turboharger for some time. The area next to the starter is a very tight fit, with the starter mount in firm contact with the intake tube. Was able to get the intake distribution assembly to fit by starting with the silicone around the distribution assembly, putting the assembly under the engine mount cross tube, then working the turbocharger end.
George suggested loosening the starter to allow it to clear enough to push the silicone into place. The port-side distribution assembly to intake pipe connecting silicone tube must be pushed out of the way to permit loosening of the starter mounting bolts.
With the starter loose, the hose clamp could also be put into place, providing a vibration wear shield for the silicone tube.

  Mar 19, 2019     Port Side Baffle 'tuck in' - (1 hour) Category: Engine

Removed port-side rear baffle and reinstalled the baffle by tucking tab into the super-tin next to cylinder fins. No additional trim to the baffle part was required. Oil line bulkhead fitting aligned with hole in baffle. Replaced side baffle on AeroVee.

  Mar 09, 2019     Reinforce oil filter mount - (1.5 hours) Category: Engine

Cut a scape section of C-channel to stiffen oil filter and turbo cooling reservoir mounting plate. Aligned and drilled mounting holes for oil filter. Left inlet hose length and routing. Outlet hose length needs shortend.

Removed turbocharger extended sump, using original flat outlet. Replaced 45 elbow with a straight fitting. Adjusted pickup hose mounting clamps.

  Jan 12, 2019     Turbocharger Mounting - (1.5 hours) Category: Engine

Working on clearing the conjested area around the turbocharger to intake manifold connection. Looking at two options;
1) Changing the cold-side port to vertical rather than 45 degrees. This option may require a 90 degree silicone adapter.
2) Cutting exhaust to move turbo mounting flange by 0.40 inches (least desirable)

  Jan 05, 2019     Turbo Radiator/Plenum - (0.3 hour) Category: Engine

Secured turbocharge radiator to plenum with self-taping sheet metal screws.

  Dec 16, 2018     Mount/Plenum for Turbo Radiator - (3.1 hours) Category: Engine

Bent 0.025 sheet to a 1" angle, cut 2" long. Cutouts for lines, riveted to plenum. Added #8 nutplates to corners for mounts. Added metalized duct tape at corners to seal holes. Mounting plan will use short lengths of angle secured to cushion clamps on engine mount tubing. Mounting location is targeted around lower starboard section of engine mount outboard of the secondary coil position.

  Dec 15, 2018     Set Cooling Lines for Turbo - (4.0 hours) Category: Engine

Found the Sonex turbo cooling parts list to be incorrect for several parts. The cooling pump in/out is closer to 5/8"; the electrical terminals to the pump are incorrect in the parts list;
Purchased one foot lengths of 5/8" and 1/2" silicone tubing for turbo cooling lines. The 5/8" fits a Prius pump inlet/outlet. Transition 5/8 to 1/2" tubing with a barbed reducer, then from to a 1/2 x 3/8' barbed reducer to 3/8" which will fit to the surge tank and radiator connections.

  Dec 09, 2018     Set Nutplates on Turbo Coolant Catch Can - (0.3 hour) Category: Engine

Set a pair of 1/4" nutplates on the turbocharger cooling circuit catch tank.

  Dec 09, 2018     Master Contactor/Fuse Mount - (0.8 hour) Category: Engine

Set #8 nutplates on contactor sub-assembly. Updrilled contactor sub-assembly mount for riveting to battery mounting braket. Countersunk rivet holes to maintain clearance on inside of mount for battery to set flush.

  Dec 01, 2018     Waste Gate Actuator Sense Port - (1.0 hour) Category: Engine

Cleaned and opened the turbocharger waste gate sense port with a 1/8" NPT tap to extend the barbed turbo charger pressure port connection away from the crowd of clamps around the turbo inlet. Added a 1/8"NPT x 2" brass nipple and 1/8"NPT x 1/8"NPT elbow. The brass hose barb connction was then moved to the end of the elbow.

  Dec 01, 2018     Turbocharger Fitup - (1.0 hour) Category: Engine

The outlet pipe of the stock exhaust from the turbocharger does not clear the engine mount structure. Sonex sent a blank (no exhaust pipe) flange in order to weld an exhaust pipe that would clear the engine mount tubing.
I found that the blank flange thickness would provide just enough spacing to enable the stock flange & pipe to clear the engine mounts.
In fitting the flange stack, one of the holes on the blank flange required drilling oversize to 3/8". Drilled with a cobalt drill bit with Boelube as a HSS bit simply overheated in the stainless.
Stacked the blank turbocharger exhaust flange and exhaust flange with pipe to turbocharger. Used 5/16" x 1.25" exhaust bolts from JEGS. Will likely replace a bolt with a stud in order to hang the stack during assembly.

  Nov 13, 2018     Research alternate turbo cooling radiator mount - (0.3 hour) Category: Engine

Looked for alternate locations for mounting the turbocharger bearing cooling radiator. The radiator is used at the end of a flight for 20 to 30 minutes. The factory recommended location on top of the engine compartment seem too prominent a location for the short period of use. An acceptible location for the plenum appears to be the lower starboard side of the motor mount. Three cushion clamps, several small fabricated struts may enable placing the radiator out of the way of other accessories.

  Nov 03, 2018     Starboard Cylinder Heat Temp Thermocouples - (1 hour) Category: Engine

Blocked starboard intake ports to prevent chips from entering. Drilled #36 holes 9/16" deep for AeroConversion thermocouple mounting hole. Installed thermocouples with supplied self-tapping screws. Marked cylinder number and RDAC input point on thermocouple wire with printed heat shrink tubing.

  Nov 03, 2018     Cooling Pump Test - (1.0 hour) Category: Engine

ested the Prius pump that will be used to circulate cooling fluid through the turbocharger after shutdown.
Used a Toyota turn signal connecter obtained here (https://www.amazon.com/Connector-2-way-Toyota-Signal-90980-11162/dp/B01E3C6YS2) to power the pump.
Initial connection to a motocycle battery that had been on a solar trickle charger found that the pump would not turn. Placing the pump in a dog's water bowl proved unsatisfactory, with a surge of water every second or so.
With a voltmeter across the battery, it was determined that a meager 11 volts was supplied to the pump. Placed a charger across the battery for an hour and a half, until an indicated 12 volts on the meter. Second wet test in a plastic container proved a good flow through the pump. Good water-tight connection at the turn signal power fitting.
As a side note, this pump - ordered as suggested from the Sonex part list, requires 5/8" diameter silicone tubing to properly fit the pump ports. The 1/2" tubing specified by Sonex will not fit the inlet ports of this pump.

  Nov 03, 2018     Aft oil line clamp - (1.3 hours) Category: Engine

Made a short bracket from scrap 0.060" Al to bolt into existing engine case threaded hole to hold cushion clamp. Put a bend in the clamp to keep oil line from contacting nearby exhaust pipe.

  Oct 21, 2018     Remove Turbo, Tap Exhaust Bolt Sockets - (0.5 hour) Category: Engine

Removed turbocharger to run a tap in the five 5/16" x 18 TPI holes that secure the exhaust flange. Removed oil lines, air line, flange bolts, and waste gate beacket. Removal route was down through the starboard side. A little twisting to orient for removal. Planning how to remove the coolant catch can with turbo in place. Tap bound at depth > 1/2" on most holes. Rust/scale/paint cleaned from threaded holes. Applied silver anti-sieze compound to exhaust bolts.

  Oct 21, 2018     Oil return line from turbo - (1.5 hours) Category: Engine

Instaled aeroquip straight fitting on AN6 braided hose and connected to 45 degree elbow on turbocharger drain. Measured length to oil pump, cut and installed 90 degree aeroquip fitting.
Secured line to bottom of engine with cushioned clamp, and to motor mount member with double cushion clamps. Adjusted oil line between clamps to free contact with exhaust and engine mount.
Used technique demonstrated by Dick Koeler in an EAA video for holding cushion clamps together.

  Oct 20, 2018     Turbo Shroud - (1 hour) Category: Engine

Rolled ACV-T05-44 turbo shield into a cylinder over the edge of a sawhorse. Bent, drilled, and riveted angle attachment to sheld. Moved mounting location 3/8" inboard due to additional turbo outlet flange thickness used to clear motor mount tubes. Updrilled mounting hole to 21/64".

  Oct 20, 2018     Secure Oil Lines - (1.5 hours) Category: Engine

Used the techique demonstrated by Dick Koeler in an EAA video (https://video.eaa.org/detail/video/5033854492001/easy-adel-clamp-installation) for attaching Adele clamps.
The method was very effective, enabling easy instalation of cushioned clamps securing braided oil lines to engine mount tubes. Secured clamps with #8 x 3/4# machine screws with torque washer and fiber nut.

  Oct 20, 2018     Install Port CHT thermocouples - (0.5 hour)       Category: Engine

Used an extended length #32 drill bit to drill port cylinder heads inboard of spark plugs. Attached spring-loaded drill stop to bit allowing 9/16" depth. Held vacuum near bit to capture chips. Used Sonex Aircraft supplied #6 x 1/2" self-tapping screw to secure thermocouple eyes to cylinder head.

  Sep 23, 2018     Plenum for Turbo Cooling Fan - (3.0 hours)       Category: Engine

Remade plenum to the dimensions of the radiator in hand rather than the Sonex plan sheet (duh). Cut a 4-1/8" diameter hole for the fan with a flycutter. Cut the standoffs from the fan enabling a 1/2" recess. Installed nutplates to attache cooling fan with #8 screws.

  Sep 23, 2018     Oil Vapor Vent Line - (0.8 hour) Category: Engine

Cut and bent 5/8" AL tubing for oil vapor vent. No tubing bender large enough, used the round back of a chair as a bending aid. Not optimal but functional.

  Sep 22, 2018     Install AN4 oil lines - (3 hours) Category: Engine

Installed solid aluminum AN4 oil line from engine tee fitting to bulkhead fitting secured to hole drilled through baffle and rear engine flange.
Made up braide hoses using the techniques in this video: https://youtu.be/KwmvRWuAwno
Briefly considered the "Koul Tool" suggested in the video, but at $29 ea and a set of three for $79 it seemed a ridiculous price per fitting. Helpful were the video suggestions. Used a cutoff wheel on a die grinder to make square cuts in the braided line clamped between vise jaws identical to those in the video, Clamping the braided lines and fittings during cut and assembly made those stages of the process simple. Must wear safety glasses as there is substantial debris as the braiding is cut.
A convenient small tube of assembly oil from JEGS was also very helpful. The assembly lube is a light mineral oil. The oil providing greater confidence that the braided line isn't pushed out of the socket by the tapered inlet as happened on a previously made dry AN6 fitting. Marked the hose at the socket line and checked for movement after assembly.

  Aug 18, 2018     Turbo/Intake/Starter Fit-up - (3.0 hours) Category: Engine

Cut additional material from the 45 deg silicon adapter to relieve the clearance with the engine flange.The waste gate pressure port is very difficult to install and clamp due to interferance with the intake silicone adapter.
Purchased a 1/8" x 2" tipple to extend the hose barb, however the threading in the turbo did not seem to match.
Tried carving away at some of the rubber tube and using silicone grease but was still unable to get the clamp in place.
The starter motor edge also impinges on the intake manifold adapter. With the turbo loose on its mounts it is almost impossible to fit the silicone adapter in place. I'm guessing some fit problems are due to distortions in the exhaust manifold.

  Aug 18, 2018     Turbo Cooling Circuit Plumbing - (1.5 hours) Category: Engine

Using a straight AN6 into an AN6 elbow didn't provide clearance with the firewall. A 45 degrees AN6 fitting was used as illustrated in the AeroVee manual. However, a 30 second operation to screw in the fitting turned into 30+ minutes as there was insufficient clearance when threading the 45 into the turbo body.
Was unable to install an AN6 45 elbow without removing material from the turbo housing. Best tool for removing the majority of material was a Vixen file to take off the edge of the edge of the housing.

  Aug 18, 2018     Install oil pressure sensor - (0.8 hour) Category: Engine

Determined that the Sonex supplied 1/8" street tee would not align the flare fitting without another full turn. Afraid of cracking the engine case with the NPT thread, a close nipple and female tee were substituted which allowed the arrangement to tighten and orient fittings without fear of splitting the crankcase.

  Aug 17, 2018     Tubocharger Fit - (2.5 hours) Category: Engine

Worked on fitting the turbo charger to the engine compartment. Installed turbo oil sump with high temperature silicon sealant as a gasket material. Allowed silicon to set before attaching long sump. Clearance issues with the waste gate actuator bracket required several attempts at removing and smoothing the bracket angle on a grinder.

  Aug 17, 2018     Manifold Alignment - (0.5 hour) Category: Engine

Checking final fitup of intake manifold indicates the 45 degree silicone elbow needs additional trimming to remove contact between the intake collector and the engine acessory plate.

  Aug 17, 2018     Install bulkhead to engine case - (0.5 hour)       Category: Engine

Step drilled engine baffle to case mount through #6 baffle mounting hole. Then step drilled 1/4", 3/8, 7/16" and 19/64". Deburred engine case flange and rear cooling baffle plate.

  Aug 12, 2018     Spark plug passthrough - (0.5 hour) Category: Engine

Drilled and filed hole for spark plug wire and jacket to pass through a rubber grommet on the starboard side cooling baffle at the corner.

  Aug 04, 2018     Cooling Baffle - (3.0 hours)       Category: Engine

Add #6 nutplates and rivets to secure starboard and front baffle segments.

  Jul 28, 2018     Secure Port Side Baffle - (1.5 hours)       Category: Engine

Drilled and riveted angle to port side baffle. Installed nutplates for two # 6 screws on fore and aft ends.

  Jul 15, 2018     Baffle Support - (1.5 hours) Category: Engine

Installed baffle support to port side of engine from piece of aluminum angle. Angle bolts to engine head and riveted to baffle.

  Jun 10, 2018     Mark Dip Stick - (0.5 hour)       Category: Engine

Paul Thonnard, whom I had met at the Sonex Flight firewall-forward seminar in Lee's Crossing, MO, spent the evening in Charleston. Paul visited the hangar and we moved the fuselage onto the relatively level runway, and added two quarts of oil. Per the AeroVee instruction, set the dipstick low-level mark with the edge of a triangular file.
Paul worked on removing flaking ceramic engine paint from the AeroVee's magnesium block.

  May 28, 2018     Cooling Baffle Fitup - (3.5 hours)       Category: Engine

Align cooling baffle parts, file and trim pieces to fit. Left corner required a good bit of trimming around exhaust.

  May 13, 2018     Initial Fence Baffle System Installation - (4.5 hours)       Category: Engine

Installation and fit-up of the AeroVee cooling baffle system, began with rear left and right fence progressing around right side. Opening for oil return pass through needs increased opening to not interfere with fence positioning. Will need some sort of grommet to seal tubing to fence.
Research revealed that the lower sheet metal supplied by Sonex is not required for a top mounted cooler.

  May 12, 2018     Secondary Ignition Trigger Orientation - (1 hour)       Category: Engine

AeroVee pg35. When swinging the propeller by hand, it was found that the flywheel trigger contacted the starter housing's unmachined face which was incorrectly fit up with the solenoid outboard due to the stator plate incorrectly clocked to one position CCW. The stator plate interference with the starter solenoid was the cause of the incorrectly installed starter.
The starter was unbolted from the frame and the starter face with a machined clearance was on the outboard side. This led to discovery of the incorrectly clocked stator plate.
The stator plate was unbolted and clocked to the correct position.
The ACV-Z01-12 screws were left loose waiting for Loctite 242.
Starter awaiting reinstallation.

  Apr 21, 2018     Oil Return Line - (1 hour)       Category: Engine

Cut and installed oil AN6 flared aluminum return line.

  Mar 18, 2018     Turbocharger Mount - (1.3 hours)       Category: Engine

Filed and smoothed turbocharger flange support bracket edges with Scotchbrite wheel. Turbo flange hole was undersized, opened to 3/8" with drill. Secured waste gate actuator to bracket. Loosely bolted waste gate actuator mount, support bracket to exhaust flange using supplied intake gasket.
Am unable to fit the lower exhaust pipe, as there is no clearance between its path and the engine mount struts.

  Mar 04, 2018     Drill & Tap Oil Return - (0.6 hour)       Category: Engine

Drilled a series of increasing holes to 7/16" dia for 1/4" NPT tap into the magnesium engine block. Stuffed a rag in the filler port and held a vacuum nozzle on bit/tap to prevent chips from falling into engine. Hole located 1-1/2" below fill fitting. Tap was very easy, used a 1/2" socket to drive the end of the tap. Attached NPT to AN-6 flare, 90 degree elbow.

  Mar 04, 2018     Check Upper Turbo Exhaust - (0.5 hour)       Category: Engine

Checking the alignment of the upper turbocharger exhaust revealed a problem in clearing the engine mount structure. With the exhaust manifold in place, fit the turbocharger with inlet gasket, flange brace, and waste gate actuator. Then fit upper exhaust without graphite gasket.
Hung a plumb bob to check inboard wall clearance. Found a half pipe diameter interference with the engine mount. Sent finding to the factory to determine disposition.
Also appears that the lower spring attachment hoops are located where the springs would contact the framing.

  Mar 03, 2018     Mount Exhaust Manifold - (2.5 hours) Category: Engine

Mounting exhaust manifold to Aerovee with exhaust flange gaskets. Drilled flange keyholes to round the straight section of 'keyhole' to provide thread clearance for square bolt alignment.
Much pulling and pushing of exhaust tubes to align and install bolts. Technique for final flange (#1 cylinder in this case) was to pull flange into position with opposite flange bolt in place. Pull the exhaust pipe while tightening opposite flange bolt. Last flange bolt could then be aligned and tightened.
Flange bolt bottomed before bolt head engaged flange facing on cylinder #1. Used washer for thread take up. May try running a tap into the hole.

  Feb 03, 2018     Engine Mounting, XNB-P10 - (2.2 hours) Category: Engine

Used 1/4" reamer to clear mounting bolt holes. Placed rear engine mount rubbers. Up drilled the Aerovee lifting hole in magnesium web in case to accommodate swivel shackle pin. Secured HF 500# rated chain hoist to ceiling beam. Lifted engine and maneuvered fuselage closer to engine. Engine pitches forward when hoisted from the single point, used roller stand to help square the Aerovee mounts. Sprayed door and lock lubricant (wet/dry TFE lube) on rubber mounts to help move them into position when securing with AN4-35 bolts.
Bolt threads bottomed when tightening nut, will replace with AN4-34.

  Sep 24, 2017     Bolt Engine Mount to Firewall, XNB-P10 - (1.5 hours) Category: Engine

Determined the correct bolt size for the top engine mounts to be AN5-27A and AN5-33A for the lower. Fourth hole needed slight alignment drilling to fit bolt.

  Aug 20, 2017     Install Time-Serts, Starboard Side - (2 hours)       Category: Engine

'Loosely' reinstalled left head (no torque), removed right. Drilled spark plug holes and installed Time-Serts. Filed threads where thinned aluminum exposed sharp edges to combustion chamber.

  Aug 19, 2017     Install Port Head Time-Sert - (1.5 hours)       Category: Engine

After reading Mike Smith's post on Sonex Builder's Net (http://sonexbuilders.net/viewtopic.php?f=7&t=3850&p=29348&hilit=time+serts#p29348) and recalling my own life experiences with aluminum thread galling on motorcycles, I concluded that adding Time-Sert thread inserts to the AeroVee would be inexpensive and prudent. Removed right side head, cut and installed Time-Sert 42123 M12 X 1.25 X 15.0 SP TIME-SERT (WASHER SEAT) from Thread Kits Company (https://www.threadkits.com/catalogsearch/result/?q=42123&cat=) using a liberal amount of WD-40 to lubricate and flush cuttings.
Thanks to Mike Smith (mike.smith208@comcast.net) for the loan of his installation tool!

  Oct 22, 2016     Push-rod Assembly - (1 hour)       Category: Engine

Measured and cut push-rods to length. Measured length using the push-rod tool - cut at bottom of socket hex.

  Oct 15, 2016     Assembly - (8 hours) Category: Engine

My time-lapse assembly videos:
1. https://www.youtube.com/watch?v=faYICUGHNoo
2. https://www.youtube.com/watch?v=BQNv6iA_N6A

  Oct 14, 2016     Determine Cylider Head Volume - (2.5 hours)       Category: Engine

Determined cylinder head volume using a sheet of Plexiglas with a hole and a syringe.
Cylinder 1:
Cylinder 2:
Cylinder 3:
Cylinder 4:

  Oct 13, 2016     Trim cylinder head studs - (2 hours)       Category: Engine

AeroVee 2.1 Turbo page 23. 9:00 - 10:53 pm Installed starboard head to check stud dimensions. Removed 0.275" (7mm) from each stud.

  Oct 13, 2016     Evaluate & Dress Heads - (2.5 hours)       Category: Engine

Received head assemblies from AeroConversions. Evaluated the clean up work to the castings. Cut, filed, and smoothed cooling fins around dual plug cuts. Fit-up of heads to cylinders indicates the studs will be much longer than necessary.
Measured stud length to leave 2-3 threads. Removed 0.275 in (7.0mm) from each cylinder stud. Procedure to cut studs to have 2-3 threads showing is to chuck stud into padded vise, measure with micrometer, cut, chuck into lathe, dress end with file, Applied Curil K2 to case end and snug into case saver. Pushed #4 cylinder bottom case saver into case, pulled it back and snugged into case.

  Sep 26, 2016     Setup Compression Ratio - (4.5 hours)       Category: Engine

5:45 am weighted piston + rings + wrist pin:
Cyl #1 518.0 gr; Cyl#2 517.6 gr; Cyl#3 518.8 gr; Cyl#4 518.8 gr
Deck height on all cylinders +/- 0.001" of 0.0. No additional shims. Assembled a shim pack for 7.0 : 1 compression ratio. Page 22 indicates a shim stack of 0.17. With shims from kit plus additional 0.01" shim stack is 2 x 0.06 + 0.04 + 0.01. Will re-evaluate after measurement of combustion chamber volume and re-calculate compression ratio.

  Sep 25, 2016     Assembly, Torque Gland Nut - (11.5 hours)       Category: Engine

Assembly of external engine components, manual pages 29-35 and 40-42 while waiting on back-ordered head assemblies to ship.
To torque the gland nut, used the body weight torque technique. The method is modified from Wilson "How to rebuild your Volkswagen Air-Cooled Engine". Rather than pushing down on the 'cheater bar', the AeorVee was bolted to a wood frame with two anti-torque plates holding the motor in place.

A 1/2" breaker bar with a cheater made from a motorcycle fork tube was used as the lever. Desired torque in the neighborhood of 300 ft-lbs (315 ft-lbs, Wilson, pg126); 315/200 = 1.575 * 12 = 18.9 = 19 inch lever arm marked on fork tube. Alignment mark on breaker/fork. Used a seated pull-up to use my body weight to supply the correct amount of force. Discernible movement of the gland nut, movement between marks on nut and flywheel.

  Sep 24, 2016     Case Prep & Assembly - (12 hours)       Category: Engine

Finished case prep by grinding/sanding/Scotchbrite outside of engine case. Wash with mineral spirits followed by a wash with soap & water. Checks for loose casting flashing. Taped and painted cylinders and engine crankcase with ceramic engine paint. Prepare crankcase for assembly, mount port side case to engine stand. Assemble bottom end. Used Curil K2 rather than the recommended Permatex Aviation sealant for case haves, obtained good sealant squeeze-out around case perimeter.

  Sep 23, 2016     Crankshaft & Connecting Rod Assembly - (3 hours)       Category: Engine

Crank placed in freezer for 24 hours prior to assembly.Timing gear and prop hub heat soaked in oven at 500degF for two hours to get a blue color on the cam timing gear. Main bearing #1 oil supply hole enlarged to 1/8" with the outboard end chamfered slightly. Assembled with JEG's assembly lube, part number: 555-28000. Engine assembly stand slide bolt was loose resulting in crank falling onto my foot/toes after assembly. (ouch!).

Used Plastigauge green to check main bearing bores. Clearances OK. Cleaned bores, connecting rod layout per photo. Connecting rods caps with hex nuts and ACV-P06-33 part number, but no 'star' head. Used red Loctite and 'clean' torque progression per step 5 to 8/15/24/30 ft-lbs.

  Sep 23, 2016     Case prep - (6 hours)       Category: Engine

Grind, sand, Scotchbrite polish external crankcase casting irregularities. Washed case in mineral sprites. Rinse with soap and water. Taped and painted case with black ceramic heat paint. [Later regret for painting the case, as the paint readily flaked off.]

  Sep 22, 2016     Cam and Crank Assembly - (1.5 hours)       Category: Engine

Polish stamped number with emery cloth while turning camshaft in lathe. Assembled bearing, cam drive gear with wavy washers and prop hub per AeroVee 2.1 turbo instructions on page 10. Needed 425 degF in oven to get the camshaft drive gear to turn blue.

  Sep 20, 2016     Pickup AeroVee Kit - (1 hour)       Category: Engine

Pickup AeroVee at XPO Logistics. Pallet fit in the back of 2003 Toyota Rav4 with the rear seats removed.