Cotton AeroVee 0795

[Bryan Cotton]

I agree with the last 2 posts. Those bolts are M8 X 1.25 right?

[bakfly]

I came up with a solution for the pushrods. I put another shim under the rockers and the alignment was still good. Now I have a boatload of adjustment as the motor runs in. Adam now knows how to find TDC and adjust valves:


As a kid I learned good judgement to avoid stripping holes. How? Well, I stripped a bunch of holes, of course. Adam did his first one on the fuel pump blockoff plate. All the threads came out nicely like a spring on the bolt. We have a helicoil lesson in our future. I assume they have metric helicoils.

.
Just be careful,having another shim under the rockets brings the rockets and valve clearance adjusting screws higher up and there is a possibility they hit the rocket cover preventing the valves from closing, especially when the rocket cover gaskit is compressed a bit. This happen to me and I lost compression on 3 cylinders.
Peter,
Sonex 19-8464, Aerovee 2.1
Flown 140hrs

[Bryan Cotton]

Thanks Peter, I will look out for that.

[Bryan Cotton]

Grinding down the flange of the oil cooler:


Next we had to bolt it to the case. No stripped threads tonight.


Motor on bench so we can put on the rear main seal, shims and flywheel.

[Bryan Cotton]

I didn't read far enough ahead to buy a VW oil seal installation tool. So, we made one. First, a little holesaw to make room for the crank pins. Next, a medium one to make a notch. Finally a big one to set the OD of the tool:


The middle holesaw is taped to the plywood while seated in the notch.


Now I just need Locktite 272 and a 300 ft-lb torque wrench.

[rizzz]

Now I just need Locktite 272 and a 300 ft-lb torque wrench.

Hi Brian,
I doubt many of us have actually used a 300ft-lb torque wrench for this job. They are very expensive.
If you put an extension on a normal wrench/spanner with the correct socket attached, you can calculate how far from the center of the socket you have to push down with your full body weight to achieve the required torque, here's how I did mine:
http://mykitlog.com/users/display_log.p ... 484&row=57

I believe that's what most people do.

[Bryan Cotton]

Thanks Michael. I'll weigh Adam since I don't want to go near the scale.

[sonexsteve]

I've just done this job a few weeks ago, getting hold of the Loctite 272 was a major hassle, eventually found a substitute Kerry approved of. As for the torquing up to 227 ft/lbs I found an air powered impact wrench, sold for doing up vehicle wheel nuts, in a local technical chain store, that on its 'high' setting was rated at 300 ft/lbs - so I just used that. Can't say whether it leaks or not, I've yet to run the engine.

[Bryan Cotton]

The fine art of RTV / caulk application:


Torqued!

[Bryan Cotton]

We got the magnatrons, accessory plate, and intake manifolds installed last night. Magnatrons are gapped and torqued.