Cotton AeroVee 0795

[Area 51%]

Try this.....You don't need to have the crank installed in the case to set the end play. It's easier to assemble the crank, bearing, shims, and flywheel on the bench and check the clearance with a feeler gauge there.

Did you remove the temper in the pushrod by heating it up to install the ends?

[Bryan Cotton]

Try this.....You don't need to have the crank installed in the case to set the end play. It's easier to assemble the crank, bearing, shims, and flywheel on the bench and check the clearance with a feeler gauge there.

Did you remove the temper in the pushrod by heating it up to install the ends?

I set it to .005 last night. We did not heat our pushrods for installation. A local VW guy seems to think we should have.

[Bryan Cotton]

Here is that bad pushrod:

[Bryan Cotton]

One of the things I'd like to figure out is why I can't get our cruise oil pressure below 60 psi. So I've decided to pull the galley plugs and have a good look.

galley plugs out.png (1.11 MiB) Viewed 1483 times

galley plugs front.png (1.05 MiB) Viewed 1483 times

I used this as a guide:
https://www.huelsmann.us/bugman/FilterTech.html

Sonex tech support said I shouldn't pull the plugs. But I did anyway. Also I used this slide hammer from HF:
https://www.harborfreight.com/slide-ham ... 56894.html
Worked great!

One interesting thing was the small plug on the front of the engine, where the oil pump out galley intersects the front bearing galley, had a pipe thread tap instead of a plug. I had to put some heat on the case to get it out. It was brass I think.

[kmacht]

I pulled the galley plugs on my case when I rebuilt the motor. There was actually quite a bit of metal shaving debris in there. I’m not sure it affected anything as the debris was packed at the ends where it wasn’t restricting flow but cleaning it all out provided some peace of mind.

Keith
#554

[Area 51%]

One interesting thing was the small plug on the front of the engine, where the oil pump out galley intersects the front bearing galley, had a pipe thread tap instead of a plug. I had to put some heat on the case to get it out. It was brass I think.

Behind that pipe plug, there used to be a restrictor as delivered from VW. It's typically removed to enhance the oil flow to the front bearing.

That's right..........I never throw anything away.

[Bryan Cotton]

Behind that pipe plug, there used to be a restrictor as delivered from VW. It's typically removed to enhance the oil flow to the front bearing.

That's right..........I never throw anything away.

So - I should remove it? I haven't checked if my case has it yet.

[Area 51%]

If you have a pipe plug, the restrictor has more than likely already been taken out.
The stock blocks have a pressed-in plug in that location.

[Area 51%]

Another thing, The Aerovee assembly manual used to call for enlarging the oil supply hole in the nose bearing. Probably still does. When I pointed out to Sonex back in 2017 that my pre-assembled crank did not have the larger oil hole in the bearing, they said they discontinued that practice.

I removed the bearing and up-drilled the hole.

[Bryan Cotton]

My restrictor was out.

For those who are able to do the full flow mod without disassembling the case, I'm not worthy. There was no scary debris in the galleys before but there is now!

For now I'm just going to plug the holes. 3 down, 6 to go.