Apr 09, 2024     Added air filter - (2 hours)       Category: Engine

Removed 90 degree nozzle towards front air inlet
Added K&N filter with aluminium tube extension

  Apr 08, 2024     Added baffling to cylinders #1 and #3 - (2 hours) Category: Engine

Added more cover for the #1 and #3 cylinders to bring temperatures HIGHER and bring in line with #2 and #4 ... needs testing

  Apr 06, 2024     Completed Piston/Cylinder Upgrade - (10 hours)       Category: Engine

Finished wiring cleanup
Installed baffling
Installed plenum
Installed cowling
Did 1hr test flight
CHTs good for cylinders 2,3,4, never above 380
CHT for cylinder 1 too low, never hit 300 ... removed metal tape on front inlet
Oil temp went too high at 225 ... removed lower inlet blocks, removed throttle body elbow and increased outlet opening at bottom end of cowling
Had lower spark plugs fouled, so removed, cleaned and reinstalled them

  Apr 05, 2024     Continued piston/cylinder upgrade - (12 hours)       Category: Engine

Measured valve lash, all within tolerance, mostly in the 70s
Installed valve covers and tidied up loose items
Test ran engine for leaks, no leaks found
Removed previous CHT sensors
Disconnected EGT sensors as bundled together with CHT sensors
Resoldered all EGT & CHT connections, with new shrink tubing ... solder joints / sensor readings need monitoring
NOTE - right side bundles are #1 EGT & CHT, #3 EGT & CHT, left side mixed up #2 EGT with #4 CHT, #4 EGT with #2 CHT
Re-bundled all wires
Replaced all spark plugs with new ones
Mounted CHT sensor rings on underside underneath the 18 to 14mm adapters
Torqued adapters per SDS manual
Replaced valve covers with newly cleaned, sand blasted and painted covers

  Apr 04, 2024     Upgraded pistons/cylinders with High Compression - (12 hours)       Category: Engine

Took off cowling, plenum and baffling
Took off bottom parts, intake tubes, pushrod tubes and exhausts
Removed cylinders and pistons
Installed new pistons and cylinders
Discovered need for different CHT sensors, no ports for bayonet style sensors ... Ordered 18mm sensors
Reinstalled all bottom parts
Tried to deflate hydraulic lifters to install rocker arms but inflated again too fast
Pushed in valves instead and then installed rocker arms

  Jun 22, 2023     Made & installed aluminum baffles - (4 hours) Category: Engine

Replaced metal tape with metal baffles
Baffles are for undersides of cylinders, both front and rear
Baffles are held in with safety wire
Also added significant metal tape around cyl #4 front

  Jun 07, 2023     Added metal tape covers on front cylinders - (1 hour)       Category: Engine

Found significant temp differences between front and pack cylinders
Added tape on front to get better flow in back

  May 24, 2023     Connected & installed air filter - (3 hours)       Category: Engine

Cut & floxed in a screen
Connected throttle body with canopy inlet with baffling material
Cut foam filter material and stuffed into air intake

  May 13, 2023     Installed air intake connection to cowling - (1 hour)       Category: Engine

  Apr 12, 2023     Resin wiped lower cowling - (1 hour)       Category: Engine

Per Jason Skiby, resin wiped lower cowling for better cleaning

  Mar 16, 2023     Tidied Up Engine Lines & Wires - (4 hours) Category: Engine

Went around engine and tidied up all lines, wires and put them in place with zip ties and clamps

  Mar 19, 2023     Torqued & Safety Wired Engine - (4 hours) Category: Engine

With Kevin's help, went around engine, torqued all bolts and nuts and safety wired everything including prop
NO ACCESS to oil pressure nut, next time when engine off!!!

  Mar 25, 2023     Torqued Spark Plugs - (1 hour) Category: Engine

  Mar 28, 2023     Mounted oil hatch - (4 hours)       Category: Engine

Riveted in piano hinge for hatch
Drilled holes for SkyBolts
Riveted in SkyBolts for locking hatch

  Mar 26, 2023     Installed AntiSplat kit - (4 hours)       Category: Engine

Bought kit after recommendation from Jim Patillo
Connects to engine blow and goes into exhaust

  Mar 25, 2023     Installed exhaust heat shields - (4 hours)       Category: Engine

Purchased at ACS after recommendation from Kevin & Ross for heat shielding fuel injectors
Installed them and turned around items in the way

  Mar 23, 2023     Installed exhaust heat muff - (1 hour)       Category: Engine

Designed with ACS referred welder from Vegas
Installed onto exhaust ... Do I need a bracket to hold it?

  Mar 22, 2023     Finished rough cowling work - (40 hours)       Category: Engine

Made injector bump
Primed outside
Fit exhaust pipes
Installed funnel for intake air
Test fit intake rings

  Mar 15, 2023     Completed Plenum - (8 hours)       Category: Engine

Added horizontal carbon front plate to stop air from escaping

  Mar 11, 2023     Lots more plenum and cowling work - (40 hours)       Category: Engine

Redid plenum to accommodate spark plugs
Made ring holders
Faired cowling
Made plenum “pimples”
Glued carbon sides to plenum top

  Feb 27, 2023     Plenum & Cowling Layed Ip - (40 hours)       Category: Engine

Plenum carbon cured
Cowling fiberglass over rings

  Feb 19, 2023     Adding intakes on cowling - (16 hours)       Category: Engine

  Feb 12, 2023     Fit cowling - (16 hours)       Category: Engine

Trim top cowling
Fit bottoms cowling
Screw into place

  Feb 02, 2023     First engine run … SUCCESS - (8 hours)       Category: Engine

Installed throttle bracket
Primed with oil
First engine start a little leak on oil filter bracket fixed after tightening
Watch engine crank fire leak
Alternator not charging

  Jan 23, 2023     Installed prop extension - (4 hours)       Category: Engine

Installed pressed fitting lugs
Drilled holes in bolt tip for magnets
Epoxied magnets into holes and measured gap
Tightened bolts to 30 lb ft

  Jan 23, 2023     Hung engine - (8 hours)       Category: Engine

Mounted return fuel line
Mounted oil pressure line
Mounted oil pressure wiring
Hung engine with aircraft grade bolts … NOTE start tightening bottom bolts first!!!

  Nov 03, 2022     Installed various SDS EFI parts - (4 hours) Category: Engine

Injectors
Fuel rail fittings
Injector fuel fittings
Injector plugs/wires
Hall sensor bracket
Hall sensor ... needs tightening

  Oct 16, 2022     Fixed bolts for throttle body - (3 hours)       Category: Engine

Removed old studs
Replaced with new allen bolts

  Jul 17, 2022     Test hung engine - (2 hours)       Category: Engine

Couldn't use new bolts, not enough clearance
Used temp bolts and hung engine

  Jul 14, 2022     Torqued everything according to SDS manual specs - (1 hour) Category: Engine

Spark plugs 19 ft lbs
Spark plug adapters 25 ft lbs ... per service bulletin on April 26/19 http://www.sdsefi.com/cpi.htm
1/2 bolts on engine 180 in lbs (vacuum cover, throttle body)
7/8 bolts on engine 110 in lbs (magneto covers, starter, vacuum pump cover)

  Jul 14, 2022     Installed more engine components - (6 hours)       Category: Engine

With new o-rings, bolted on vacuum pump cover and throttle body
Made a bracket for the fuel distribution block
Mounted fuel distribution block
Tightened 1 exhaust nut for all 4 pipes ... needs more work

!!! CAN'T TIGHTEN ONE NUT ON THROTTLE BODY !!!

  Jul 13, 2022     Continued engine components install - (8 hours)       Category: Engine

Installed tapped intake elbows
Torqued starter, magneto cover, oil screen cover etc according to https://www.csobeech.com/files/TCM-Torque-SB96-7D.pdf
Installed intake tubes with new rubber fittings and hose clamps

  Jul 08, 2022     Tapped fuel intakes - (2 hours)       Category: Engine

Took off and marked fuel intake elbows
Eric tapped them per SDS instructions

  Jun 27, 2022     Installed oil screen cover - (1 hour)       Category: Engine

Bolted down oil screen block cover
Insalled oil temp sensor

  Jun 22, 2022     Installed new oil filter adapter - (1 hour)       Category: Engine

New adapter installed
Bottom screw not tightened

  Jun 17, 2022     Installed REAL pushrod tubes - (5 hours)       Category: Engine

Installed half of them with Kevins help
The rest installed on my own ... need to keep an eye out for leaks

  Jun 15, 2022     Removed rudder pedals & tabs - (3 hours)       Category: Engine

Removed a few myself, but also got help from Joe, such a nice kid

  Jun 15, 2022     Removed oil screen housing - (1 hour)       Category: Engine

Turns out oil screen housing interferes with firewall
Removed housing, need a block off plate

  Jun 14, 2022     Mounted alternator gear assembly - (1 hour)       Category: Engine

Installed gear assembly ... COTTER PIN NEEDS TO BE CHECKED

  Jun 11, 2022     Installed 2 of 4 new pushrod tubes - (4 hours)       Category: Engine

Removed old pushrod tubes
Installed new REAL pushrod tubes
Removed intake tubes & cleaned them ... not ready install until injectors arrive and are installed