Welcome to my builders log for Sonex S/N 767. It won't be as big as a real 767 but if you scale the speed I bet it will be almost as fast
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Last weekend, I installed the oil pump. I have a top-mounted oil cooler, so the pump is a straight pump, not the maxi oil pump. The installation manual mentions using form-a-gasket #3 or flange sealant. The Sonex assembly video mentions using Fuellube, available from Aircraft Spruce. I ordered some of this for assembly. The Fuellube …
29.6.2024 20:28Oil PumpLast weekend, I installed the oil screen and oil sump. This was pretty simple. I had ordered a sump cover with dual ports. One thing I noticed, consistent with the assembly video, is that the nuts do not engage far enough into the studs for the nylon to catch. The assembly manual mentions the use …
29.6.2024 20:09Oil ScreenI have been working on the rocker shaft installation for a week or two now. Based on everything I’ve learned, I suggest following the AeroVee manual. It just works. Being a mechanical engineer, I put too much thought into this process and concluded that what is presented in the manual is correct, even if it …
Continue reading "Rocker Shaft Installation"
27.1.2024 20:11Rocker Shaft InstallationI worked on installing the cylinders, pistons and cylinder heads on one side of the engine today. My goal was to complete one side before starting the other. The reason for working on one side at a time was to try and ensure a good seal for the cylinders. I figured that if the cylinders …
Continue reading "Installing Cylinders and Heads"
7.1.2024 23:42Installing Cylinders and HeadsI started today by getting out the cylinders heads. I want to have them ready to install right after I install the cylinders. Why? The cylinders are installed using Permatex Aviation Form-A-Gasket #3 and I would like to install the cylinder heads and have them secured while the Permatex cures. Since I only work on …
Continue reading "Cleaning Cylinder Heads"
6.1.2024 17:37Cleaning Cylinder HeadsI continued working on assembling the crankcase today. Previously, I installed the crankshaft and camshaft. Today, I finished fitting the flywheel. This took a bit of polishing of the dowel pin holes as I could not get the flywheel to fit onto the end of the crankshaft. Once the flywheel was installed, I used my …
Continue reading "Crank Case Assembly"
16.12.2023 18:21Crank Case AssemblyI started the crank case preparation shortly after receiving the engine kit back in August. I inspected the interior of the case for any remaining machining chips. I blew the case out with compressed air and spent time using a deburring tool to clean up any edges or holes that appeared to have burrs. I …
Continue reading "Crank Case Preparation"
12.11.2023 12:27Crank Case PreparationI continued working on the connecting rod assembly. After loosening all of the fasteners I cleaned the mating surfaces and installed the bearings. Next, I decided I wanted to check at least one of the journals for clearance. I purchased some plastigage online and proceeded to assemble the first rod on the crank with a …
Continue reading "Connecting Rod Assembly"
11.11.2023 20:51Connecting Rod AssemblyToday I did a little bit of prep work for the crank assembly. I located all of the connecting rods, the rod bearings and the crank shaft. I opened up the connecting rods and loosened the bolts. The nuts were quite tight, so I needed to clamp the connecting rod in the vice between two …
Continue reading "Connecting Rods"
29.10.2023 18:50Connecting RodsThe title is a bit of a misnomer. I didn’t need to assemble the prop hub as I ordered the crankshaft with the prop hub installed. But I did complete the rest of the crank shaft assembly. I used mineral spirits, as directed in the assembly manual, to clean the crank and I used pipe …
Continue reading "Crankshaft Assembly"
17.9.2023 21:03Crankshaft Assembly