AeroVee Engine Assembly
After a complete inventory of the parts I started by washing down the engine case. The engine case was
washed (with mineral spirits) and dried. The cylinders, which come assembled with pistons, piston pins
and rings, were disassembled and cleaned with mineral spirits. The cylinders were taped, then dusted with
a VERY LIGHT misting of Barbecue black Paint as recommended by Sonex. Remember the cylinders
were only lightly misted for protection/appearance. I did not want to impede the cooling ability by adding
to much paint around the cooling fins.
washed (with mineral spirits) and dried. The cylinders, which come assembled with pistons, piston pins
and rings, were disassembled and cleaned with mineral spirits. The cylinders were taped, then dusted with
a VERY LIGHT misting of Barbecue black Paint as recommended by Sonex. Remember the cylinders
were only lightly misted for protection/appearance. I did not want to impede the cooling ability by adding
to much paint around the cooling fins.
Next the cylinders were checked with an inside micrometer. All cylinder diameters were within .003 of each
other. Then ring gaps were checked and found to be within the recommended limits of between .012 and
.022. After the checks were preformed I coated the rings, pistons and cylinders with clean engine oil and
reassembled them. Each cylinder was then packaged in a protective pack to prevent any contamination from
shop dust/aluminum dust while awaiting assembly in the engine.
other. Then ring gaps were checked and found to be within the recommended limits of between .012 and
.022. After the checks were preformed I coated the rings, pistons and cylinders with clean engine oil and
reassembled them. Each cylinder was then packaged in a protective pack to prevent any contamination from
shop dust/aluminum dust while awaiting assembly in the engine.
After de greasing the engine case with mineral spirits and letting it dry for a
full day I masked off all the openings and painted the case with barbecue flat
black. I know it looks a little gray in the photo however it is flat black. I will
allow the paint to cure for the next two days before I assemble anything in
the case.
full day I masked off all the openings and painted the case with barbecue flat
black. I know it looks a little gray in the photo however it is flat black. I will
allow the paint to cure for the next two days before I assemble anything in
the case.
At left is the painted case after all the masking tape and paper was removed.
At right is the crankshaft after assembly of the forward gears, bearings,
spacer lock ring and propeller flange. All was going very well until time for
the prop flange. It took several good blows with a mallet and a chunk of oak
to get this home. The impact wrench finished the job. with the prop flange is
tight against the Oil slinger.
At right is the crankshaft after assembly of the forward gears, bearings,
spacer lock ring and propeller flange. All was going very well until time for
the prop flange. It took several good blows with a mallet and a chunk of oak
to get this home. The impact wrench finished the job. with the prop flange is
tight against the Oil slinger.
At left is the completed crankshaft prior to installation. After the ring gaps
were checked and found to be within limits, it was time to reinstall the
pistons into the cylinders. First rings were staged at 120 degree separation
then coated with engine oil.
were checked and found to be within limits, it was time to reinstall the
pistons into the cylinders. First rings were staged at 120 degree separation
then coated with engine oil.
At far left the ring compressor is coated with oil and then clamped to
compress the rings. There should only be enough pressure applied to
compress the rings smaller than the cylinder. Once the rings clear the
cylinder wall I remove the compressor and slide the piston the rest of
the way in. (see below far left)
compress the rings. There should only be enough pressure applied to
compress the rings smaller than the cylinder. Once the rings clear the
cylinder wall I remove the compressor and slide the piston the rest of
the way in. (see below far left)
Next all the rods were cleaned and any burs were
removed. Rod bearings were cleaned and visually
inspected. Then each rod assemble was plasti gauged
against the Crankshaft Journal.
removed. Rod bearings were cleaned and visually
inspected. Then each rod assemble was plasti gauged
against the Crankshaft Journal.
Thats when all things came to a halt. After #1,#2 and #3 rod to crank clearances
were checked and found to be within limits, the #4 rod locked tight to the crank. The
plasti gauged was so badly distorted on one side it could not be read. This is why we
follow the assembly manual word for word. A quick e-mail to Jeremy at sonex and
new rods and bearings are on the way. I will return the ones in question so that Sonex
can follow up. Now thats service.
were checked and found to be within limits, the #4 rod locked tight to the crank. The
plasti gauged was so badly distorted on one side it could not be read. This is why we
follow the assembly manual word for word. A quick e-mail to Jeremy at sonex and
new rods and bearings are on the way. I will return the ones in question so that Sonex
can follow up. Now thats service.
All the parts needed were received from Sonex. They really
stand behind there products. I will continue on the engine
assembly after completing wing rigging and landing gear.
Please check back at a later date for more on the engine
assembly and installation.
stand behind there products. I will continue on the engine
assembly after completing wing rigging and landing gear.
Please check back at a later date for more on the engine
assembly and installation.
| NOTE: There are only two authorities on the proper assembly and installation of the AeroVee Engine and they are Sonex and Aero conversions. Any question on assembly and or installation should be directed to the Sonex Tech Assistance Line. The engine assembly manual MUST be used and not this site. |
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