Cotton AeroVee 0795

Discussion of the Aerovee kit engine.

Re: Cotton AeroVee 0795

Postby Bryan Cotton » Tue Jul 30, 2024 2:50 pm

It's much harder to put the motor on its nose in the drill press, so I drilled all 4 plugs by hand. Actually for the small plugs I went right to the 1/16 NPT tap without drilling. But I could not get the 3/8" NPT tap started. As I was getting frustrated I put it aside until after Oshkosh and ordered some 10MM bolts so I could get the case nose down on the drill press. What I did on the other side was to use the chuck to press/center the tap into the hole as I turned it. That worked great.

Here I've bolted an angle across a couple of 10MM holes that serve some purpose on the car. I clamped a second angle to the first one. I also found some nifty large flat head torx 6mm screws from my Saturn junk box and screwed them in by the crank exit/snout.
angles and screws on nose.png


Here it is in the press.
nose down on drill press.png


I clamped those angles to the table and shimmed below the screws & snout. I made the screws level with the snout.
clamped and shimmed to drill press.png


Lunchtime over - will tap it tonight.

I'd rather be lucky than good.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Re: Cotton AeroVee 0795

Postby Bryan Cotton » Tue Jul 30, 2024 10:49 pm

I've successfully tapped the last two oil galleys. Back:
large back plug installed.png


Top:
top plug installed.png


I saw nothing scary in the galleys, so not sure what was causing my high oil pressure.

Doing this job in the drill press is key to making it go well.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Bryan Cotton
 
Posts: 5489
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton AeroVee 0795

Postby bvolcko38 » Wed Jul 31, 2024 12:02 pm

How did your bearings and journals look? Did you plastigauge them?
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Re: Cotton AeroVee 0795

Postby Bryan Cotton » Wed Jul 31, 2024 12:41 pm

bvolcko38 wrote:How did your bearings and journals look? Did you plastigauge them?

They looked ok. I did not plastigauge them.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Bryan Cotton
 
Posts: 5489
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton AeroVee 0795

Postby Area 51% » Fri Aug 02, 2024 11:08 am

Are you going to re-use your cam and lifters?

If not, there is a better option for the camshaft. To begin with, the names "Eagle" and "Engle" get confused a lot. To be clear, the cam named after the symbol of the U.S.A. is a CB Performance unit. The other, well, is just the other.

Engle has a cam available with nearly identical lift/duration/overlap characteristics. Pricier I'll grant, but it's advantage is it's forged with flat spots to miss the connecting rods. The Aerovee assembly manual would have you assemble the engine with the Eagle cam, then rotate it and listen for contact between the cam and rod ends. If there is contact, simply disassemble the motor and grind the offending matter from the cam. No mention of how to actually check the clearance between the two.

My new Engle cam is sitting here awaiting employment @Area 51%
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Re: Cotton AeroVee 0795

Postby Bryan Cotton » Fri Aug 02, 2024 12:11 pm

Area 51% wrote:Are you going to re-use your cam and lifters?
@Area 51%

Yep. I had no clearance issues in the first 270 hours.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5489
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton AeroVee 0795

Postby Bryan Cotton » Sat Aug 03, 2024 6:40 pm

I have a set of Great Plains intake manifolds I want to try.
intake spacers in progress.png


I made spacers. Left a gap between the front and rear cylinder. Wondering if this will help balance the mixture.
intake spacers done.png


Aeroconversions parts for comparison.
Aeroconversions spacers.png
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5489
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton AeroVee 0795

Postby Area 51% » Sun Aug 04, 2024 7:17 am

Stock VW manifolds had a slot machined between the intake ports. Quite possibly for that very reason.

I figured, if it's good enough for VW, it's good enough for me. I chiseled a groove between the holes on my Great Plains manifolds simply out of respect for the engineers at VW. No digital information down to the tenth of a degree, but my plugs were all very evenly colored.

If nothing else, it sure looks nice not having a square peg in a round hole. .
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Re: Cotton AeroVee 0795

Postby Bryan Cotton » Sun Aug 04, 2024 9:39 am

How far did your groove go? All the way? Any pictures?

Area 51% wrote:If nothing else, it sure looks nice not having a square peg in a round hole.


Yeah that always bugged me.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5489
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton AeroVee 0795

Postby Area 51% » Sun Aug 04, 2024 11:47 am

It simply bridged the gap between the ports. 3/16 X 3/16 slot comes to mind. No pictures and I can't seem to lay my hands on them, but I know they are in the 10lb pile somewhere in this 5lb bag I call a workshop.
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