Sonex-A purchase - What to look for

[kmacht]

As I see it, the elephant in the room is Chinese parts made of Chinese materials.

I don't believe that the EMPI heads being manufactured in China is the cause of burnt exhaust valves on an aerovee but if you want US made heads just give MOFOCO a call. They will send you a set of US cast and manufactured heads that work with the aerovee including having them machined for the proper CC's, 92mm bore and using stainless intake and exhaust valves. They will even cut the second set of spark plug holes in each head for $100. These are the same heads that Sonex used to sell years ago before switching to EMPI. Two new 042 heads setup for an aerovee with dual plugs from MOFOCO is still cheaper than buying the Chinese manufactured EMPI heads from Sonex with their markup. The only downslide to the 042 heads is that the web between the valve seats is small and tends to develop a non critical crack over time. You could also buy the 040 or 041 heads setup for an aerovee with slightly smaller valves for less money if that is a worry for you.

Keith
#554

[pappas]

I was glad to replace the original MOFOCO heads supplied by Sonex with the EMPI's. The EMPI's casting was noticeably more dense than the MOFOCO's. I realized that when I drilled and tapped an oil separator return line into the back of the head. Much better bite for the fitting.
I believe the valves have a better seating surface with the EMPI's.

[Area 51%]

CB Performance is my go-to head store. The heads are cast by Autolinea who also manufactures the cases and have an extra cooling fin. Nine versus the 8 on a stock head.
They do, however, need to be sent elsewhere for the extra spark plug holes. DO NOT tell CB Performance they are for an airplane. They will not sell you the heads.

[Bryan Cotton]

CB Performance is my go-to head store. The heads are cast by Autolinea who also manufactures the cases and have an extra cooling fin. Nine versus the 8 on a stock head.
They do, however, need to be sent elsewhere for the extra spark plug holes. DO NOT tell CB Performance they are for an airplane. They will not sell you the heads.

Which ones? There seem to be many options.

[Kai]

The further I go down this rabbit hole, the more I realize that buying an airplane with an AeroVee was a foolish and ill-conceived move on my part. Sonex advice is that if you don’t have the requisite ability or desire to build one of their airplanes, perhaps you shouldn’t own one, either. I get that now.

I´m about to get a bad conscience here- I surely hope you don`t feel the pletoria of comments on these pages have contributed to mask the essence og VW-1 ownership in a Sonex.

I think Dale & Dee are hitting the nail on the head with their posting. Now, before you do anything rash like spending the rest of your life in a monastry or something, think of all the options you have: educate yourself and get the VW back to life, or educate yourself and install a different brand. That´s for the engine side. Then there is the airframe: since it is your behind on the line up there, get yourself educated and learn about upgrades, service, repair, and maintenance.

Addendum:
There are two major sources of knowledge here: one of them is Sonex. At least do a builders course at their premises- I did it in 2004 (dear me, 20 years ago!) and learn the rock bottom basics of airframe building, sheet metal forming, and blind riveting. There is nothing difficuilt about this, and pester those guys with questions: they are more than willing to answer. The other one is local EAA chapters. Become a member and start going to their meetings. People will be eager to help in any way possible: nothing beats working on other people´s engines!

My two bits

Bryan Cotton informs Sonex does not offer their builders course any more. See below. I should have checked-sorry!

Kai

[WesRagle]

Hey Hambone (If that is your real name ;-)

The further I go down this rabbit hole, the more I realize that buying an airplane with an AeroVee was a foolish and ill-conceived move on my part. Sonex advice is that if you don’t have the requisite ability or desire to build one of their airplanes, perhaps you shouldn’t own one, either. I get that now.

Listen to Kai. You just learned a lesson that you would have to learn, to one degree or another, regardless of which experimental airplane you bought. That is, when it comes to experimental aircraft, you can't buy the dream, you have to live the dream. A rather abrupt lesson in your case but don't let it get you down.

So, before you waste too much time with self loathing, go back to your previous attitude:

Well, I’m now on a quest to build up the AeroVee to be as reliable as possible.

Dig in. Before you know it you will be back in the air.

All the Best,

Wes

[Area 51%]

Which ones? There seem to be many options.

The 044. Not the Panchito (or whatever it's called). I also sprung for the titanium retainers. No good reason other than they are a couple of ounces lighter. .

[Bryan Cotton]

There are two major sources of knowledge here: one of them is Sonex. At least do a builders course at their premises- I did it in 2004 (dear me, 20 years ago!) and learn the rock bottom basics of airframe building, sheet metal forming, and blind riveting.

It's not been offered for years.

[bvolcko38]

At our low rpm 3000 +/-, why do we need dual ports and bigger valves. This is for high rpm power, no?

[Kai]

It's not been offered for years.

My bad! I´ll edit accordingly.

Thanks
Kai