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Building Integrity
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Date:  7-10-2014
Number of Hours:  6.50
Manual Reference:  Section 2
Brief Description:  Prop flange exchange and extension

After a Nightmarish 30 minutes trying to break the prop hub bolt loose, I decided that contrary to instruction manual's advise, 2, 6 foot breaker bars still wouldn't do the job. In fact I bent the prop removal tool they sent with the engine. My gosh!
Instead of breaking my back any longer, I went to Lowes and picked up a 350ft/lb impact wrench. You should have heard me laughing when I pulled the trigger and in 1 nanosecond the bolt came lose. a Kindergardener could have done this! The manual states to torque the bolt to 221 ft/lbs, and then to re-torque it after the first 10 and 20 hours of flight. I tell ya what, I'll be damned if I have to remove my entire prop assembly and buy a set of $100 bolts everytime I do, just to "check" the torque.
I had to remove the prop flange because it's not the right bolt pattern and the factory forgot to put the right one on and had to send this one to me as a replacement. Check out the difference in pic #3! I now have SAE2 with 7/16 bolts. Or SAE5.
After a Very thorough cleaning and Corrosion-X Bath, I installed the new Prop flange, hit it "lightly" with the impact wrench until the M6 retaining bolt threads lined up, then threaded it in with locktite blue and was ready for the Saber extension.
I went with the 4" extension because UL has NOT tested the engine with extensions yet. At my 100 hr I may bump it up to the infamous 8", we'll see. I meticulously installed the extension using 10lb torque values stepping up to 44lbs final. She looks gorgeous and is begging me for a prop...and safety wire :)
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A failed attempt with bars and cheaters

A failed attempt with bars and cheaters

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A walk in the park! I'm in love.

A walk in the park! I'm in love.

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Now THAT's a flange...on the left.

Now THAT's a flange...on the left.

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