Builder's Log
DateAssemblyInstructionPartDescriptionLinks
3/25/2011 Engine UPS Delivered 5 boxes from Sonex - Engine Order Photos
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3/26/2011 Engine Inventory Engine Order Photos
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02/14/2014 Engine P01 P01

P30 Aerovee Engine Installation.
I attached the engine to the engine mount. I inserted the bolts, rubber mounts, washers and nuts through the engine mount and engine.

P14 Battery Box.
I made the top attach hold down strap. I fitted and riveted it to the box and fuselage.

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02/15/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Oil Temp Sender.
Decided that I will drill and tap the oil block off plate on the front of the engine for the oil temp sender.
Prop Hub Inserts.
I used a 5/16th bolt, washers and a 5/8th socket to be sure the inserts were properly and fully inserted.
Intake Manifold.
I used some alcohol and rags to clean out the inside of the intake manifold. I put the hoses on the intake elbows. I placed the intake manifold in place. I then determined where to drill a hole in the tab to attach it to the engine case bolt. I drilled the hole and put the manifold back to check it's placement. It looks like it will work ok.

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02/17/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Intake Manifold.
I installed the intake manifold. I attached the hoses and clamps. I attached the metal tab to the engine block.
Electrical.
I started to figure out where I will put things on the firewall.

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02/20/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Oil Cooler.
I bent the Oil Cooler mounting flange on the bending brake.

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02/22/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Oil Cooler.
I fitted the oil cooler to the mounting flange. I located it where it would not hit the exhaust manifolds. I had to notch the forward flange to match the hole for the oil drain / oil temp plug. I drilled the holes to attach the oil cooler. I cut out the area for the air to flow through the oil cooler. I only cut three sides of the opening so that I could bend the cut out piece to make the air deflector. I used a piece of cardboard to try to determine where I need to notch the air deflector. I bent, cut and filed to get the air deflector to fit.

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02/23/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Oil Cooler.
I did a final trim and fit of the oil cooler. I installed the bolts and nuts to hold the cooler to the shroud / flange. I bolted the assembly to the engine.
Gascolator.
I installed the 45 degree elbow and the drain valve to the bottom of the gascolator. I also installed the plug to the top of the gascolator.

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02/24/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Gascolator.
I located and drilled the holes through the firewall for the gascolator firewall pass through adapter. I used files to make the main hole large enough for the adaptor. I bolted the adaptor to the fire wall. I attached the gascolator to the adaptor.

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02/25/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Air Cleaner.
I drilled and tapped a hole to attach the air cleaner assembly. I installed the air cleaner assembly.
Oil separator.
I drilled, up drilled and deburred the holes to attach the oil separator to the firewall. I need to get the bolts and anchor nuts to attach the oil separator. For now it is attached with clecos.
Coils for the Secondary Ignition.
I cut the stand offs. I drilled, up drilled and deburred the top holes to 1/4th size. I inserted temporary bolts in the top holes.

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02/26/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Coils.
I drilled and deburred the holes for the bottom bolts for the coils. I then installed the bolts.
RDAC.
I located and drilled the holes for the RDAC. I used clecos to temporarily hold the RDAC to the firewall. Voltage Regulator. I located and drilled the holes for the regulator on the firewall. I deburred the holes and installed the bolts.
I will order anchor nuts for all the items on the firewall.

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02/28/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Engine Mount Bolts.
I removed the temp castle nuts and replaced with the lock nuts.
Master Solenoid.
I located on the fire wall the position where I wanted to install the master solenoid. I drilled and deburred the holes. I installed bolts to attach it to the firewall.
Alternator Capacitor.
I am going to try installing B&C's Over Voltage and Filter Kit. I located and drilled a hole to mount the capacitor for that kit.
Firewall Hardware.
I am going to order and install anchor nuts for all items installed on the firewall.
Fuel Tank Straps.
I glued felt to the straps for the fuel tank.

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03/08/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Spent the day working on installing the anchor nut for the items bolted to the firewall.
I placed a brass bushing on a washer head bolt/screw to hold the anchor nut in place on the firewall while I drilled the rivet holes.

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03/10/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Finished installing the anchor nuts on the firewall. I put the RDAC and Oil Separator back on the firewall.

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03/12/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Gascolator.
I determined that the firewall adaptor would not work. The inside portion went too far into the area between the rudder pedals. I am concerned that a passenger might hit the fuel line with their foot. So I have decided to remove it. I am going to attach the gascolator directly to the firewall. With a 90 degree fitting the fuel line will be next to the firewall. Therefore the fuel line will be protected by the rudder pedals. I am going to place extra pieces of stainless steel on both sides of the firewall. Today I made a pattern out of aluminum. I installed it with the gascolator to be sure it will work. When I get the stainless steel I will make two of them. I will put one on each side of the firewall. This should strength and stiffen the firewall at the gascolator location.
Throttle Trim Attachment.
I drilled the holes in a 2 x 2 x 1/8th angle for the Throttle, Mixture and Trim Controls. The will be attached to the bottom of the panel in the middle. I bolted the Throttle and Trim to the angle.>/p>

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03/14/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Gascolator.
I got the stainless steel. I cut two 3.5" x 3.5" squares. I drilled the holes and used files to debur and match the holes. I put some RTV between the firewall and the squares. I bolted the gascolator and the squares to the firewall.

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03/24/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Oil Sump Plate.
I installed a plug in the extra hole in the sump plate. At this time I do not plan on using it for a return from the oil separator.
Oil Cooler.
I installed the bushings and nipples into the oil cooler for the hoses. I also installed the nipples into the oil pump for the hoses. I made the two hoses that will connect the oil cooler to the oil pump.
Panel.
I also painted the corner and cross pieces. I did a second color coat to the panel.

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04/04/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Throttle and Mixture Cables.
I drilled holes through the firewall and installed cable safes. I had to enlarge the hole in one of the cable safes for the throttle cable.
Aero Injector.
I enlarged the cable holding hole for the mixture cable. I installed the ball end of the throttle cable into the slide of the Aero Injector. I attached the Aero Injector to the intake manifold. I attached the mixture cable. Both cables are run but the throttle cable is not attached at the throttle quadrant.

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04/12/2014 Engine P01 P01

P30 Aerovee Engine Installation.
Throttle and Mixture Cables.
I shortened the throttle cable housing to fit. I worked on adjusting the throttle cable attached at the throrrle quadrant. I used some temporary zip ties to see where the cables will go.

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05/26/2015 Engine P01 P01

Did Service Bulletins.
ACV-SB-061714 - Replaced Cap Screws for Trigger Shaft Assembly.
ACV-SB-051415 - Check of Primary Ignition Modules.
Service bulletins were completed as required.

Set the prop hub to TDC for cylinder #1. This is need for installation of Propeller.

Install the Aerovee CHT Probes per the instruction sheet.

Placed the rear baffle in place to start the fitting.

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05/27/2015 Engine P01 P01

Engine - Baffles. Continued working on the engine baffles.

Gear - Main Gear Fairings. Finished fabricating the main gear fairings. Installed the main gear fairings.

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05/29/2015 Engine P01 P01

Gear - Main Gear Fairings and Pants. Did some fitting and trimming on the main gear fairings. Also trimmed a slight curve on the main gear pants. This allows access to the air valve stems without removing the pant. Also trimmed the pant where it meets the fairing.

Engine - Baffles. Continued working on the engine baffles.

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06/04/2015 Engine P01 P01

Engine - Baffles. Continued working on the engine baffles.

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06/05/2015 Engine P01 P01

Installed propeller.

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06/06/2015 Engine P01 P01

Checked the tracking of the propeller.

Put the cowling back in place.

Got the plane ready to be stored for the summer. This all the work I will do until sometime in the fall. The hangar is getting too hot for this old man ;)

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10/05/2015 Engine P01 P01

Worked on fitting and fabricating baffles.

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10/06/2015 Engine P01 P01

Worked on fitting and fabricating baffles. Stopped early because of thunder storm

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10/07/2015 Engine P01 P01

Worked on baffles. Located and drilled the holes in the exhaust for the EGT probes. Installed the EGT probes and checked for clearance from the cowl.

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10/16/2015 Engine E01

Switched the prop bolts from AN5-41 to AN5-40. They are still too long. Used extra washers as spacers. Ordered AN5-37 bolts.

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10/22/2015 Engine P01

Worked on replacing the cylinders.

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10/23/2015 Engine P01

Finished installing the new cylinders. Started putting everything back on the engine. Adjusted the valves.

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10/24/2015 Engine P01

Checked the valve adjustment. Continued putting everything back on the engine. Baffle fences.

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10/27/2015 Engine P01

Installed a bolt in the bottom tail section at the tail skid. All fasteners are now installed for the aft bottom skin. Hooked up the oil pressure sender. Filled the engine with oil per the areovee manual instructions for initial oil fill. Also per the instructions used the starter to check for oil pressure on the EMS. After 3 10 second runs on the starter oil pressure was registering on the EMS.

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10/28/2015 Engine P01

Put 1 gallon of fuel in the tank. Check for leaks to the shut off valves. Did the final connection and adjustment of the throttle and mixture cables. Pulled the mixture to the cut off position. Open the fuel shut off valve. Had on fitting at the gasolator leaking. Tightened the fittings on the inside fuel line. Drained the gascolator. The gascolator quick drain is now dripping. Turned off the shut off valve.

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10/29/2015 Engine P01

Removed the quick drain valve. Found debris in the O ring. Cleaned and put back the quick drain valve. Leak/drip fixed. Removed the oil sender. Put some teflon paste on the treads of the oil sender. Put the sender back. Checked the ground continuity of the sender body to the engine bock ground. Ground connection is good.

Picked up the exhaust pipes from being ceramic coated. Bolted the exhaust pipes to the engine.

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10/30/2015 Engine P01

Removed the wing tip lights and prepared the wings to go to the painter. Secured the exhaust pipes with the springs. Drilled a hole in the firewall and attached springs from the exhaust with a clamp. Installed the EGT sensors. Attached the EGT wires to the RDAC module.

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10/31/2015 Engine P01

Attached the CHT wires to the RDAC module. Made and attached the oil Temp sensor wire to the RDAC module. Did the first engine start. The engine did start but there are several issues. The throttle does not move correctly. The engine idles rough. Will work on sorting out these issues.

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11/05/2015 Engine E01

Worked on determining why the throttle sticks. Removed the throttle cable. Checked move movement of the throttle with the cable straight. Still sticks. Not because of any bend in the cable. Removed the Aero Injector. Remove the bolts holding it together. Worked the cable to see why it is sticking. Nothing obvious. Removed the needle. Polished the needle. Installed the needle. The slide now moves freely. Put the Aero Injector back together. Installed the Aero Injector back on the engine. Installed the mixture and throttle cables. It now appears that the throttle moves smoothly.

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11/07/2015 Engine E01

Fabricated and installed the crankcase breather tube in and out of the oil separator. Started the engine. Oil preasure was 38psi. Oil temp got up to 89 degrees. Throttle was completley stuck with the engine running. Without the engine running the throttle moves freely. The engine was running at about 1400 RPMs. After shut down no oil or fuel leaks were found.

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12/24/2015 Engine P01

Test Run for engine.

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1/29/2016 Engine

Worked on trimming engine baffles.

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2/4/2016 Engine

Trimmed the exhaust pipes to be 2" out of the cowling. Measure ARM lenghts for the weight and balance.

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2/8/2016 Engine

Worked on trimming engine baffles. Used paper clips to gauge the proper gap between the baffle fence and the cowling.

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2/9/2016 Engine

Made the backing strips for the back and side baffles. Cut the rubber baffle strips for the side and back baffles. Pilt drilled and clecoed the rubber and backing strips in place for the side and back baffles. Checked the cowl for proper fit with the side and back baffles. They appear to have a nice tight fit.

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2/10/2016 Engine

Up drilled and de burred the holes for the rubber seals on the back and side baffles. Riveted the back and side rubber seals in place. Used the band saw to cut the remaining backing strips.

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2/11/2016 Engine

Worked on baffle seals for oil cooler inlet.

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2/12/2016 Engine

Finished baffle seals for oil cooler inlet. Need to flip the bottom seal. It sticks up into the flow of air.

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2/13/2016 Engine

Flipped the bottom baffle seal on the oil cooler inlet. Found some small oil leakage around the oil screen plate. Changed and torqued the nuts on the oil screen plate.

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2/15/2016 Engine

Completed fabricating and installing the baffle seals across the front of the engine. It has a nice tight fit.

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2/16/2016 Engine

Fabricated and installed a cover to place at the back of the right side baffle. This covers a hole in the engine case where the starter is located. Also fabricated a angle to support the throttle and mixture cables at the front bottom of the engine

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2/17/2016 Engine

Worked on routing and securing wiring in the engine area.

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2/18/2016 Engine

Worked on routing and securing wiring in the engine area.

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2/22/2016 Engine

Worked on routing and securing wiring in the engine area.

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2/23/2016 Engine

Worked on routing and securing wiring in the engine area.

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2/25/2016 Engine

Worked on routing and securing wiring in the engine area.

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2/26/2016 Engine

Worked on routing and securing wiring in the engine area. Also Ron Smith EAA Tech Counselor did a final inspection.

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2/29/2016 Engine

Misc to do items to finish up.

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