breeched oil gallery on new case

[n502pd]

Just got my new case on 4-28-16. Today I bagan clean up inside of case and discovered a breeched oil gallery between the center camshaft bearing boss and the rearmost top oil cooler enterance (or exit??). the breech is under the machineing for the cylinder shirt on the inside of the case. To me it looks like the machine just went too far. and opened the galery to the interior of the case. this would, IMHO, destroy any pressure in the breeched gallery and most likely fail the camshaft very quickly. I view this as a safty of flight issue and feel I should not build this case. :(

Has anyone else had this problem, if indeed it is a problem? I have built a few engines and have never seen anything like this before. Pictures on request because I can figure out how to attach them here. :?

I have of course sent Kerry my 'thoughts"!!

[surfly]

Joe,
I was also less than satisfied with the machining done on the inside of my case however did not notice a breeched oil gallery. I am finishing up my rocker arm assembly installation, which went well, and will stay tuned to your post out of interest in your case issue.
Surfly

[n502pd]

Joe,
I was also less than satisfied with the machining done on the inside of my case however did not notice a breeched oil gallery. I am finishing up my rocker arm assembly installation, which went well, and will stay tuned to your post out of interest in your case issue.
Surfly

Just this AM Aeroconversions have agreed with me that the case has been badly' violated' so to speak, and is not worthy of any further building as they said '...it will not build oil pressure'. This is a correct warranty response and I am awaiting further instructions from them on returning the case, and I suspect my only problem because of this is a couple of weeks delay in progressing on the case build. I do have a lot of other stuff to do, so my time will be occupied well, I guess!! When I get a new and good case I will post that also just to enclose the problem.

Thanks for the interest!! :)

Joe

[tmobbs]

Joe and Surfly

What serial numbers do your Aerovees have?

Tim Mobbs
Sonex#1555 TD
Aereovee #0672
Bungay, Suffolk, England

[n502pd]

Well, the serial number of mine is 0870, but the actual case serial number may be what you are asking. If so, the case serial is 09015H05, made in south america. and I really just think someone wasnt watching when they were operating the machine, and nothing to really condem the AeroVee totally at all. I had bought a brand new Chevy back in 72, and Chevy could not put a good starter on it for maybe 3 months?. The car lasted another 8 years after that with little problems. I am just saying...! :|

[n502pd]

I forgot to say in my last reply that Sonex got the incomming email from me this AM, replyed to that by 0830-ish, and has sent me the RMA number to return the bad case at 1548 today. just a little over 7 hours response isnt bad at all, IMHO. I am impressed enough to continue doing business with them in light of their warranty responces durring my build. I could not get anywhere near that good of response on my dead inwarranty maytag washer several years ago!! :D

[surfly]

Great timing! Yesterday I finished up adjusting my valve lash and installing my rear crankshaft seal only to come home and find the email from Sonex concerning the possible improper machining of my case calves. Being a retired A&P/IA and being used to years of dealing with AD's I am taking this news as just another fact of aviation maintenance. Sure I am not happy about this however I am relieved that this possible machining error inside my engine was brought to my attention before I went any further.
Keep Building!!!!!!
Surfly

[surfly]

Tim,
My engine serial # is 0841.
My case halves serial # is 08915H22
Surfly

[n502pd]

For the record, my engine serial is 0870, case number is 09015H05.
I really dont enjoy being the bearer of bad news to anyone, but I sure am glad these engine cases will (should) be inspected. :|

[surfly]

Do you have a serial # series of the affected case halves? If so my engine serial #0841 has case halves serial # 08915H22. Is the oil galley damage shown the only damage to be concerned with? How about other machining damage to look for?
It would be much more assuring for the builder/customer to have more information before he/she pulls a head and just one cylinder for a look see.