SonexBuilders.net

I just picked up my second hand Waiex B kit with the turbo Aerovee kit. I have never built a VW engine before but I have built some small block chevys and a couple others. The engine kit was partly worked on but I am going to take it completely apart to be sure that it is done correctly. There are definitely some things that were heading down the wrong path on this and I need some help understanding what is acceptable and what is not.

1. I am short one of the main bearing location pins. Easy fix I am sure but not sure where to get them.
https://drive.google.com/file/d/1gUwgXQTPGDEdWECd5bG3Um9Tl8P6NOuD/view?usp=sharing

2. One of the cam bearing is either wrong or in the wrong spot. Are these all the same size?
https://drive.google.com/file/d/1fnkMXYPR7WV1FuqMwby_jrpnTFgMq2Lj/view?usp=sharing

3. The cylinders have a little corrosion in them and I want to know if that can be honed out or if I just need a new set? If I need new then a part number or link would be great.
https://drive.google.com/file/d/1IL7msrwMf1mGSMeynIDfs0AptA0Jg6By/view?usp=sharing

4. Is the little bit of corrosion on these shims going to matter or can I just remove it with some scotchbrite?
https://drive.google.com/file/d/1zyYq2yvrVz9jug1FG9P0vxjjOStqQUMi/view?usp=sharing

5. This gasket is broken. Is this a standard part or should I get the one from Sonex?
https://drive.google.com/file/d/1QgHR3nVIz5mdBHBAu0-YURmaC_8x33mc/view?usp=sharing

6. In this video the ring in my fingers seems a bit loose but seeing how I have never built one of these I wanted to ask if it looks acceptable.
https://drive.google.com/file/d/1QvKGD-aUk6H1-V7pjkZj0fKfpyKdgto6/view?usp=sharing

Any help at all would be greatly appreciated.

Thank you,
Marc

Marc,
Hopefully you have downloaded the manual. Per the manual, the cam bearing alignment tab is filed off in the right hand case. As far as the corrosion in the jugs and shims, I'd probably just clean them off and use them. But if in doubt contact Sonex tech support.

Bryan Cotton wrote:Marc,
Hopefully you have downloaded the manual. Per the manual, the cam bearing alignment tab is filed off in the right hand case. As far as the corrosion in the jugs and shims, I'd probably just clean them off and use them. But if in doubt contact Sonex tech support.

Thanks for the response. I do have a printed out copy of the manual. I just have not read it yet but I will before I start the build. These are just a few things that looked obviously wrong based on me previous experience so I thought that I would ask the opinion of others with more experience. I am still waiting on the formal ownership transfer with Sonex so I can not bug Kerry until that is official.

Marc

That jug has good cross-hatching. Unless there are actually minute holes from pitting into the cylinder, a solvent-based clean-up and hone should likely be fine.

The shims, the same. Just clean them up. You are going to slobber sealant of some type all over them anyway.

The gasket is a bit of a pain. That is the gasket that resides between the turbo body and the exhaust pipe. They are fragile. I replaced 3. You can get them from Sonex for about $10 each. If you look online, you will not find one that looks exactly like that one.

The reason is that Sonex has our turbo machined to remove a casting that divides the waste-gate exhaust from the turbo exhaust. I think it makes the exhaust piping simpler and lighter.
However, if you find a gasket for a Garrett TB2568, you can just cut out the part that corresponds to the casting that was machined away in the turbo.

In any case, I recommend that you put a light coat of extremely high temp gasket flange sealer on both sides of the gasket and torque it down. I always keep one of those on hand cuz it takes about a week to get one from Sonex.

pappas wrote:That jug has good cross-hatching. Unless there are actually minute holes from pitting into the cylinder, a solvent-based clean-up and hone should likely be fine.

The shims, the same. Just clean them up. You are going to slobber sealant of some type all over them anyway.

The gasket is a bit of a pain. That is the gasket that resides between the turbo body and the exhaust pipe. They are fragile. I replaced 3. You can get them from Sonex for about $10 each. If you look online, you will not find one that looks exactly like that one.

The reason is that Sonex has our turbo machined to remove a casting that divides the waste-gate exhaust from the turbo exhaust. I think it makes the exhaust piping simpler and lighter.
However, if you find a gasket for a Garrett TB2568, you can just cut out the part that corresponds to the casting that was machined away in the turbo.

In any case, I recommend that you put a light coat of extremely high temp gasket flange sealer on both sides of the gasket and torque it down. I always keep one of those on hand cuz it takes about a week to get one from Sonex.

Thank you, I will look closely at the jugs for any pitting but it looks like light surface oxidation. I ordered a gasket from Sonex yesterday and will be sure to grab an extra one with my next order.

There was a post earlier today on flying behind an Aerovee. I know of a guy flying to Airventure from California. Half way there the engine failed and he was able to land safely at an abandoned airport. He changed to a Viking Honda engine and should be back in the air soon. I know of a another pilot that flew his Aerovee from California to the east coast and back with no issues. There is another pilot that has flown his aerovee for over 400 hours with no issues. I have decided to go with the aerovee myself and hope my experience is trouble free. Just build it closely following the manual.

I lost my logbook. Do I just buy a new one or is it more
involved?? Can't believe this happened.

Russ Clifford
800 hours
Sonex airframe completed and ready for engine and avionics.

Boise, ID

RJCLIFF707 wrote:There was a post earlier today on flying behind an Aerovee. I know of a guy flying to Airventure from California. Half way there the engine failed and he was able to land safely at an abandoned airport. He changed to a Viking Honda engine and should be back in the air soon. I know of a another pilot that flew his Aerovee from California to the east coast and back with no issues. There is another pilot that has flown his aerovee for over 400 hours with no issues. I have decided to go with the aerovee myself and hope my experience is trouble free. Just build it closely following the manual.

I think that it is going to depend a lot on the builder. Some people can read and follow instructions paying close attention to detail and others miss some things along the way. From what I have read about almost all of the Sonex emergencies they are usually operator error. Either in judgement or not assembling or maintaining them properly. I am documenting my build online so I hope that anyone watching might point out if I miss something or do something incorrectly long the way.

https://www.youtube.com/watch?v=Xug4ugK ... rningToFly