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TERRY'S WEB SITE
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Date: 10-25-2014
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Number of Hours: 5.00
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Manual Reference:
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Brief Description: Begin AeroVee Engine Assembly
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Begin AeroVee engine assembly.
The first page of the AeroVee asssembly instructions say that if I have the optional preassembled crankshaft, ACV-H01-20, to proceed to step 10. However step 3 (which I am to skip) says to remove the 4 hex plugs from the crankshaft, clean the passages, then reinsert the plugs with loctite. Skipping this step is ok if the step is done by Sonex when assembling the crank, but the passages were not cleaned, nor were the plugs loctited in place.
Right away I see that this is not the "elegant" engine package as advertised by Sonex.
Wash crankcase halves in parts washer, use brake cleaner to clean out oil passages. Yikes! Huge amount of metal chips in the oil passages. This could be a problem, since some of the passages are dead ended, so no way to ensure they are clean.
Best practice is to clean out these passages before installing the oil galley plugs in the case! (All oil galley plugs were already installed when the engine was received),
"Elegant" engine package? NOT !
Clean up camshaft, file off stampings as recommended in the engine assembly manual, to avoid contact with the connecting rods.
Assemble ACV-P01-49 Cam Gear to ACV-P01-72 Camshaft (assembly manual says ACV-P02-72).
Dissassemble ACV-P06-33 Connecting Rod x 4, clean all. Insert ACV-P01-59 Rod Bearing in each rod. Assemble same to ACV-H01-20 Pre-assembled Crankshaft.
Check rod side clearance to crank, all within specifications.
Install ACV-P01-86 Head Stud Kit. (This step turned out to be premature, as the studs just get in the way, so I removed them until it was time to install the cylinders).
Test fit oil pressure relief plungers. Inside of both holes have burrs from the cross drilled holes.
"Elegant" engine package? NOT !
Hone off burrs with drill rod and sand paper. Clean out oil passages again.
Install ACV-P01-58 Cam Bearing x 4 in crankcase halves.
Install ACV-P01-46 Dowel Pin x 5, 4 in right case, 1 in left case.
Install ACV-P01-48 Valve Lifter x 8 in case halves
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Camshaft & Gear Assembled #3717
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Connecting Rods Assembled to Crankshaft #3718
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