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Zenith CruZer & Sonex Logs
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Date: 12-4-2010
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Number of Hours: 3.20
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Manual Reference: aerovee
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Brief Description: Pushrods
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Began by cuttnig the pushrods to length to match the pushrod tool on the left side of the engine. Some builders have used jigs to hold the pushrod while beating in the pushrod tip, but I had no problem doing it freestyle.
I cut the rods to length with a pipe cutter, then used a 1/4" drill to ream-out the material inside the tube due to the cutting action. I then used a deburring tool to get rid of any remaining lip, and to add a slight chamfer to the insde of the tube. I then placed the formed end of the pushrod on a piece of scrap aluminum (since it's softer than the steel of the pushrod), held the tip in position, and hit it with a hammer. Once started, gave it a few good whacks to seat the pushrod ends. No bent rods.
I then installed the pushrods into the engine and made sure that the adjusters had correct tolerances, and buttoned-up the left side.
Repeated for the left. Sonex recommends cutting all 4 rods for one side of the engine to the same length, but expects the lengths to be different between sides of the engine. Re-set the pushrod tool, determined the length, and cut the four rods to length. Repeated the clean-up as above.
Did not use lithium on the ends yet - will have to pull apart and coat the ends.
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2 of 4 pushrods cut to length (w/pushrod tool)
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