May 11, 2024     Replace Mixture Control Lever and Cable Mount - (3 hours)       Category: Engine

Exchanged the mixture control lever replacing a lever with an offset to one without the offset to eliminate any potential interference with the cowl. This moved the cable position inboard about 1" necessitating making a new cable attach bracket. Remove riveted on old bracket, fabricate a new bracket, and rivet bracket to engine mounted bracket. Clock the lever to enable the full range of motion from idle cutoff to full rich. Verify the cable moves freely through the range of motion.

  Apr 30, 2024     Verify Rubber Baffle Fitment at Cowl - (.3 hour)       Category: Engine

Attach lower cowl and verify placement of the rubber baffle between the filter air box snorkel and the lower cowl air inlet.

  Apr 28, 2024     Add Filter Air Box Baffle - (1.5 hours)       Category: Engine

Add silicone rubber baffling to the filter air box snorkel to lower cowl air inlet.

  Apr 28, 2024     Move Oil Cooler Right 3/4" - (2 hours)       Category: Engine

Need to move the firewall mounted oil cooler left 5/8" to increase spacing with the mechanical fuel pump exit port. Fabricate a new and longer aluminum angle that mounts to the firewall to support the oil cooler aft mount tabs. This is a tedious location for mounting because the engine mount hinders access to the attaching hardware. Ultimately persevered and the cooler is hopefully mounted with sufficient clearance with the fuel pump. Right picture shows before moving and the left picture after moving oil cooler.

  Mar 30, 2024     Mount the exhaust hangers - (1 hour)       Category: Engine

Mount the exhaust hangers from the engine mount with Adel clamps and stainless steel hose clamps to the 4 into 1 collector.

  Mar 30, 2024     Mount Oil Cooler - (1 hour)       Category: Engine

Attach oil cooler to mounting angle on firewall and Adel clamps on the engine mount. The mount is sturdy but not easy to attach. The clearance between the oil cooler fitting and fuel pump fitting is close.

  Mar 17, 2024     Trim heat muff exit port - (1.5 hours)       Category: Engine

Trim about 5/8" off the right heat muff aft port due to close clearance with the #3 intake manifold. Attach scat tube to the port to verify clearance.

  Mar 17, 2024     Filter Air Box Cable - (1 hour)       Category: Engine

Drill the firewall eyeball pass through to 0.186 to fit the control cable. Add a brass sleeve to the screw that attaches the control cable to the alternate air door.

  Mar 16, 2024     Attach Alternate Air Door - (0.5 hour) Category: Engine

Apply RTV to the alternate air door frame and rivet frame to air box. Rivet hinge nut plate.

  Mar 13, 2024     Filter Air Box Alternate Air - (2 hours)       Category: Engine

Cut 2 11/16" hole in bottom of filter air box for alternate air door. Match drill the door frame to the air box and machine countersink the rivet holes and nut plate holes. Bend door latch to catch door. Parts ready for permanent installation.

  Mar 12, 2024     Trial Fit Exhaust to Engine - (2 hours)       Category: Engine

Received 4 into 1 exhaust. Mount the exhaust system to the engine and verify cowl and filter air box clearances. Overall fit is acceptable except for the heat muff exit is close to the #3 intake manifold. Do not torque installation until further research how to hang rear of exhaust from engine mount and whether to apply never seize compound to slip joints and header mounting studs.

  Mar 12, 2024     Rivet Filter Air Box to Top Plate - (1 hour)       Category: Engine

Rivet the top plate to the filter air box. Mount the filter air box to the FI servo and verify the air inlet lines with the cowling air scoop.

  Mar 07, 2024     Filter Air Box Fiberglass - (5 hours)       Category: Engine

Cut sides of filter air box to line with the top plate. Cleco the top plate to the air box. after applying clear packing tape to the top plate.to protect it while glassing in the cut with three layers of fiberglass mat. Over the next three days apply epoxy and mat, sand mat. After fiberglass complete paint the top plate and filter air box.

  Mar 03, 2024     Fabricate Filtered Box - (5 hours)       Category: Engine

Attach filter mounting plate to servo and clamp air box filter top plate to mount plate. Install the lower cowl and line the neck of the air box filter top plate with the cowl air scoop horizontally. Trim the neck to achieve 1/4" clearance to the cowl air scoop. Clamp the top plate to the mounting plate to prevent movement, remove both and match drill the mounting plate to the top plate. Install plate nuts and filter retainers on the top plate. Attach the mounting plate to the top plate with bolts and mount the assembly to the servo Mount the lower cowl and check the vertical alignment of the top plate with the top of the air scoop. Flute the top plate to adjust it's height to match. Remove the top plate with attached mounting plate and place the filter between the top plate and the filter air box. With clamps compress the top plate and filter air box about 1/16". The filter air box is ready to drill to the air box.

  Mar 01, 2024     Mount Aux Generator and Oil Filter - (1 hour)       Category: Engine

Mount the Monkworks generator to the vacuum pump Accessory Case. Do not torque mounting in case it needs to be removed. Attach the K&R S-15 reusable oil filter. Note location to drill safety wire attach hole. Mount the B&C crank driven alternator.

  Feb 10, 2024     Remake Exhaust Headers - (6 hours)       Category: Engine

Not satisfied with the clearances and routing, I remade headers 1-3 to provide a more accurate model and to increase the clearance from the cowl. Create construction pictures with design notes, package up the headers for shipping to Airplane Exhaust

  Feb 08, 2024     Final Exhaust Mockup Fitting - (4 hours)       Category: Engine

Complete gluing and screwing the PVC exhaust pipe mockup. Take additional pictures to document notes and mockup details to be supplied to Airplane Exhaust.

  Jan 30, 2024     Refit #2 and #4 Exhaust Primaries - (2 hours)       Category: Engine

Replace 1 1/2" PVC on #2 and #4 primaries with 1 1/4" PVC. Confer with Plane Exhaust Corp that they will replace right angle elbows with large radius turns.

  Jan 28, 2024     Mock up #1 and #3 Exhaust Primaries - (5 hours)       Category: Engine

Mock up #1 and #3 exhaust primaries using only 1 1/4" PVC pipe rather than using 1 1/2" for more complex bends.. Using one size pipe simplifies the fitting. 1 1/4" pipe has only two curved fittings: 45 and small radius 90 degree, whereas 1 1/2" has 22.5 degree and large radius 90 degree options. I plan to specify large radius for the 90 degree bends as part of the fabrication instructions. Tweak the #2 and #4 primaries layout to create more clearance between the primaries and the lower cowl.

  Jan 27, 2024     Test Fit #2 and #4 Primaries - (5 hours)       Category: Engine

Fabricate four adapters from 1 1/2" pvc pipe for fitting the primaries to collector. Test fit primaries between #2 and #4 cylinders and collector. Routing was suboptimal. I want more than 1" spacing between pipes and cowling. The efforts today were educational for how to route the pipes and notice the clearance issues.

  Jan 26, 2024     Mount Exhaust System Mockup Artifacts - (4 hours)       Category: Engine

Received a 4 into 1 exhaust mockup kit from http://www.experientalexhaust.com/. Mount four primary stub stacks to the exhaust ports. Place lower engine cowling into approximate mounting location to measure clearances from the engine to the cowling. Create temporary mount for the 4 into 1 collector supported from the engine mount.

  Jan 05, 2024     Fabricate mixture cable bushing - (2 hours)       Category: Engine

Fabricate a mixture cable bushing similar to the throttle cable bushing with a longer threaded portion for the cable.

  Jan 04, 2024     Fabricate prototype bushing - (2 hours)       Category: Engine

Fabricate from 3/4" round aluminum bar a bushing that screws on to the throttle control cable. The bushing has threads that mount the bushing to the throttle cable bracket. A similar bushing will be fabricated to mount the mixture cable.

  Dec 30, 2023     Test fit Throttle and Mixture cable attachments - (4 hours)       Category: Engine

Received clevises for mixture and throttle cables. Clock the throttle body throttle and mixture lever arms based on the cable mounting location. Both cables need additional mounting fixtures because the cable threaded ends are aft of their respective mounting brackets. The mixture cable mount needs to move left about 1" to line with the mixture lever. Fabricate bracket attached to existing mixture bracket to move attachment point 1" left. Verify throttle and mixture cables can operate their respective levers through their full range of motion. Ordered material to fabricate fixtures to mount both cables to their respective brackets. The mixture arm for the Precision Airmotive throttle body is different from the arm called out in the filter air box instructions. The good news is the new arm does not require the filter air box to be modified to correct for interference.

  Dec 29, 2023     Oil Cooler Firewall Mounting Flange - (2 hours)       Category: Engine

Drill and countersink center nutplate. Rivet left and right doublers, and three nutplates to firewall. Mount oil cooler flange to firewall.

  Dec 24, 2023     Firewall Oil Cooler Mount - (4 hours)       Category: Engine

Fabricate two doubler plates to reinforce the outside fasteners holding the aft oil cooler mounting bracket to the firewall. Drill, deburr, and dimple the firewall at the oil cooler mounting site. Will await assistance before riveting. Also need to order one K2000-3 MS21051L3 nutplate.

  Dec 22, 2023     Tentative oil cooler mount - (4 hours)       Category: Engine

Fabricate two attachment bars with nut plates. One bar will provide stabilized mounting one side of the oil cooler to the engine mount using Adel clamps. The other bar will clamp to an angle mounted to the firewall.

  Dec 21, 2023     Adjust Mixture Cable - (1.5 hours)       Category: Engine

Bend mixture cable mounting bracket to line cable with mixture control arm. Reclock mixture control arm to line up with mixture cable.

  Dec 19, 2023     Mount Fuil Injection Throttle Body - (3 hours)       Category: Engine

Mount fuel injection throttle body and cable mounting bracket. Temporarily place throttle and mixture cables to check for fit and alignment. The mixture cable bracket needs a slight bend to line the cable with the control arm.

  Dec 19, 2023     Replace starter motor - (1 hour)       Category: Engine

Replace Sky Tek starter motor with B&C starter motor.

  Dec 10, 2023     Mount engine to airframe - (3.5 hours)       Category: Engine

With assistance from Barry, remove engine from shipping crate and mount it to the airframe.

  May 06, 2023     Mount Lightspeed Ignition Modules - (6 hours)       Category: Engine

Devise a way to mount the Lightspeed brainboxes to the instrument panel ribs using piano hinges and aluminum bar. Modules can be removed by pulling the hinge pins. Hinge pins held in place with a zip tie. Defer priming and final riveting until the EMS and ADS-B modules also mounted. Due to slight variations in tolerances the modules are not interchangeable right for left.

  Nov 17, 2022     Engine Delivered - (1 hour)       Category: Engine

Received engine from shipper. Inspected engine and accessories, and reviewed documentation.

  Oct 20, 2022     Aero Sport Power Build School Day 3 - (6 hours)       Category: Engine

Aero Sport Power Build School Day 3. Witness attaching propeller and remaining cabling and plumbing. Add oil to engine. Engine run for approximately 2.5 hours in three test runs with power between 70-100%.

  Oct 19, 2022     Aero Sport Power Build School Day 2 - (5 hours)       Category: Engine

Aero Sport Power Build School Day 2. Assemble valve lifters, push rod tubes, pushrods, and rocker arms. Attach oil return lines and intake manifolds. Attach throttle body to crank case sump. Observe engine being mounted to test stand, attaching instrumentation, fuel, oil, and electrical cabling.

  Oct 18, 2022     Aero Sport Power Build School Day 1 - (8 hours)       Category: Engine

Attend Aero Sport Build School in Kamloops, BC CA. Day 1: Assemble crankshaft, connecting rods, bearings, camshaft and join crankcase halves. Assemble accessory housing including timing gears, oil pump, oil filter mount, fuel pump, vacuum pad, and prop governor pad. Assemble pistons, wrist pins, and cylinders. Attach crankcase sump.