AeroVee Engine Assembly
Page 2 of 3 pages
Click on photos to enlarge
The photo at left is showing the alignment of the timing marks
on the camshaft and crankshaft gears. The photo at right shows
the proper alignment as per the manual. During the building
process I took photos and logged them in the order tasks were
completed along with notes indicating all measurements taken,
torque settings, supplies and questions that I had asked of the
Sonex Team along with responses received. I found this to be a
great record of exactly how the engine went together for future
ref. It was also included in my builders log that I presented to
the FAA DAR during the Airworthiness Inspection and again for
my FAA repairman certificate. The FAA reps were very pleased
with the photo and note log and stated that Photos taken of me
at all levels of construction made it easy to determine that I had
met the 51 percent rule and had the required experience to obtain
my Repairman certificate
on the camshaft and crankshaft gears. The photo at right shows
the proper alignment as per the manual. During the building
process I took photos and logged them in the order tasks were
completed along with notes indicating all measurements taken,
torque settings, supplies and questions that I had asked of the
Sonex Team along with responses received. I found this to be a
great record of exactly how the engine went together for future
ref. It was also included in my builders log that I presented to
the FAA DAR during the Airworthiness Inspection and again for
my FAA repairman certificate. The FAA reps were very pleased
with the photo and note log and stated that Photos taken of me
at all levels of construction made it easy to determine that I had
met the 51 percent rule and had the required experience to obtain
my Repairman certificate
Case bolted and torqued, Just one more step completed. After
this process I again verified the crankshaft end play. It was
very easy to do at this point with a dial indicator. The reading
was right on specifications as described in the assembly manual.
this process I again verified the crankshaft end play. It was
very easy to do at this point with a dial indicator. The reading
was right on specifications as described in the assembly manual.
The photo at left shows the cylinder assembly ready for
installation into the case. NOTE: Prior to this step the Cylinder
assembly was fitted to the case to determine the proper
compression ratio. As my aircraft was to be based at an airport
with good fuel prices I opted to stay with an 8:1 ration and use
100LL. Each spacer was cleaned and inspected prior to
installation. These steps are very well documented in the AeroVee
assembly manual
installation into the case. NOTE: Prior to this step the Cylinder
assembly was fitted to the case to determine the proper
compression ratio. As my aircraft was to be based at an airport
with good fuel prices I opted to stay with an 8:1 ration and use
100LL. Each spacer was cleaned and inspected prior to
installation. These steps are very well documented in the AeroVee
assembly manual
Prior to pushing home the cylinder the piston pin retainer clips
must be installed. I had modified a pair of inexpensive long nose
pliers to accomplish this task as the pins were popping of the plier
prior to the mod. The only thing that was done was to notch the
plier tips to better secure the pin. After the assembly the pliers go
to engine tool box.
must be installed. I had modified a pair of inexpensive long nose
pliers to accomplish this task as the pins were popping of the plier
prior to the mod. The only thing that was done was to notch the
plier tips to better secure the pin. After the assembly the pliers go
to engine tool box.
The photo at right shows the cylinder installation prior the
installing the cylinder heads. A careful inspection insures that no
tools, parts or debris is within the cylinder prior to installation.
The photo at right shows the installation of the cylinder to head
compression rings installed. Head Gaskets
installing the cylinder heads. A careful inspection insures that no
tools, parts or debris is within the cylinder prior to installation.
The photo at right shows the installation of the cylinder to head
compression rings installed. Head Gaskets
| NOTE: There are only two authorities as to the proper assembly and installation of the AeroVee Engine and they are, Sonex and Aero Conversions. Any questions should be directed to The Sonex Tech Assistance line. You MUST use your assembly manual. |
