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Aerovee #7 (Engine block completion)

Posted by on January 31, 2015

Total Build Time: 832 Hours.

I received my 2nd replacement cylinder head from Sonex, cleaned it up and installed it. I purchased a compression tester while waiting for the new head so I could more accurately check and record the leakage in each cylinder.

My compression test results on the new cylinder head without any modifications were as follows (cyl #1 and #2):  80/64, 80/48.  The valves in the new head were sealing MUCH better than the previous one. I then removed the head and valves and lapped them.

Waiex-1959

Waiex-1960

 

Compression test after lapping was: 80/76, 80/69, a marked improvement. On the other side, with lapped valves, compression for #3 and #4 were: 80/77, 80/76. I was happy with these results and proceeded to finish up the engine.

The intake manifold required 2 cylinder studs per side to be trimmed for clearance.

Waiex-1957

Waiex-1958

Waiex-1961

 

Here are some pictures of the intake manifold elbows in position.

 

Waiex-1962

Waiex-1964

 

To move forward at this point, I needed to remove the engine from the engine stand. Many builders use a VW engine “rebuild stand” that would give better clearance to the back side of the engine than what I had. I built a wooden rack to support the engine off the stand, since the oil filter protrudes from the bottom.

 

Waiex-1965

Waiex-1966

Waiex-1968

 

Flywheel installation, including the 227 ftlb torquing of the gland nut.

 

Waiex-1970

Waiex-1971

Waiex-1972

Waiex-1974

Waiex-1975

 

I strapped the engine to the table and used that 2×4 bolted to the prop hub as opposite leverage to torque the gland nut.

 

Waiex-1976

 

Mounting the accessory plate and magnetos.

 

Waiex-1977

Waiex-1978

 

Alternator stator.

Waiex-1981

 

Tapping and inserting the oil temperature probe.

 

Waiex-1982

Waiex-1983

 

This is as far as assembly goes until the engine is on the airframe. It’s ready to mount!

 

 

 

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