Sonex Aircraft Aerovee 2.1 Bedienungsanleitung

AEROVEE 2.1

ASSEMBLY and INSTALLATION

ACV-R02 Rev Z. 01/14/2015 Applies to AeroVee s/n 0440 and up. Includes top-mounted oil cooler.

A Product Line of Sonex Aircraft LLC

Photo for illustration only and does not represent the specic contents of your kit.

$35.00

AeroVee 2.1 Rev Z. 01/14/2015

TABLE of CONTENTS

Contents

Your feedback is welcome and encouraged as we continue to

improve this manual. Please send comments to tech@aerocon-

versions.com. Comments will be reviewed and considered for

inclusion in future revisions of this manual.

Your success is important to us. If you have any questions

while assembling your engine do not hesitate to seek technical

support by emailing [email protected].

Trigger Shaft Installation ........................................... 34

Spark Plug Installation............................................... 35

Intake Manifold Installation ....................................... 36

Alternator Installation ................................................ 37

Firewall Preparation ................................................... 38

Voltage Regulator Installation ............................................................38

Secondary Ignition Coil Installation ..................................................38

Mounting the Engine.................................................. 39

Mount Bushings .................................................................................39

Lifting the Engine ..............................................................................39

Mount Pin Detail Drawing and Typical Installation ..........................40

Magnatron Ignition Wiring......................................... 41

Electronic Ignition Wiring.......................................... 43

Spark Plug Wires........................................................ 44

Electronic Ignition Timing ......................................... 45

Alternator / Regulator Wiring .................................... 47

Starter Installation / Wiring........................................ 48

Oil Breather Tube........................................................ 49

Oil Cooler Installation Options.................................. 50

Oil Cooler - Bottom Mount.................................................... 51

Oil Cooler - Top Mount ......................................................... 52

Oil Cooler Removal / Bypass ................................................ 55

Exhaust Installation.................................................... 56

Installing EGT Probes ............................................................ 60

Fuel Supply ................................................................. 57

Engine Cooling Bafes .............................................. 59

Engine Oil.................................................................... 60

Approved Oils - Break-in Period ........................................... 60

Approved Oils - Post Break-in ............................................... 60

Priming the Engine and Setting the Oil Level ....................... 60

Oil Changes During Break-in Period ..................................... 60

Start-up and Break In ................................................. 61

Maintenance................................................................ 62

Minimum Maintenance Interval ............................................ 62

When to Rebuild Your AeroVee ............................................. 62

Torque Values ......................................................................... 62

Troubleshooting ......................................................... 63

Electrical Schematics................................................. 65

APPENDIX A: Sonex Cowl Openings ....................... 66

Details the installation of an AeroVee on a Sonex, Waiex, or

Xenos airframe.

Revision Log............................................................... 69

Part Numbers and Packing Lists .............................. 70

Table of Contents ......................................................... 2

IMPORTANT! ................................................................. 4

AeroVee Engine Kit Documentation ...................................................4

AeroVee Serial Number .......................................................................4

Assembly / Service Resources ................................... 4

Other AeroConversion Resources ........................................................4

AeroConversions' Service Bulletins ....................................................4

Additional Resources ...........................................................................4

Specications ............................................................... 5

Weights and Dimensions ......................................................................5

Mount Dimensions ...............................................................................5

Prop Hub Bolt Pattern ..........................................................................5

General Specications .........................................................................6

Cylinder Identication, Engine Orientation, Firing Order ...................6

Operating Limitations ..........................................................................6

Before You Begin... .................................................... 7

Crankshaft Assembly................................................... 8

Cam Assembly............................................................ 10

Connecting Rod Assembly........................................ 11

Crank Case Preparation............................................. 12

Crank Case Assembly................................................ 16

Piston and Cylinder Assembly.................................. 20

Compression Ratio Chart ....................................................... 21

Cylinder Head Installation ......................................... 22

Rocker Shaft Installation ........................................... 23

Oil Screen Installation................................................ 25

Oil Pump Installation.................................................. 26

Oil Cooler Installation ............................................................ 26

Operation Without an Oil Cooler ........................................... 26

Oil Seal Installation .................................................... 27

Prop Drive Lug Installation........................................ 28

Valve Adjustment........................................................ 29

Block-off Plates and Plugs ........................................ 30

Flywheel Installation .................................................. 31

Flywheel Magnet Orientation Check ..................................... 32

Accessory Plate Installation...................................... 33

AeroVee 2.1 Rev Z. 01/14/2015

IMPORTANT!

disclosed herein is the property of the originator who reserves all pat-

ent, design, proprietary, manufacturing, use and sales rights thereto,

except for the rights expressly granted to others. This document shall

not be reproduced nor shall the information contained within be

used by or disclosed to others except as expressly authorized by the

originator.

511 Aviation Road Oshkosh, WI 54902

Phone (920) 231-8297 fax (920) 426-8333

[email protected] www.aeroconversions.com

Distributed Worldwide by: Sonex Aircraft, LLC.

www.sonexaircraft.com

Disclaimer and Limited Warranty

THE EXPERIMENTAL AEROVEE ENGINE KIT IS

SOLD “AS IS”. NO WARRANTY IS EXPRESSED OR

IMPLIED!

Sonex Aircraft LLC makes every effort to assure the supplied

components of the AeroVee Engine Kit meet high quality and

durability standards, and warrants to the original purchaser

that these components are free of defects in material and

workmanship for the period of one year from the date of pur-

chase. This warranty does not apply to damage due directly or

indirectly to improper assembly, misuse, abuse, negligence or

accidents, repairs or alteration out side our facilities, or lack of

maintenance. Due to the experimental nature of the AeroVee

Engine Kit, the end user is solely responsible for determining

suitability of application, assembly, installation and operation.

Sonex Aircraft LLC and its agents will in no event be liable

for death, injuries to person or property, or incidental, contin-

gent, special, or consequential damages arising from the use of

our product.

Sonex Aircraft LLC and its agents will not be responsible

for any incidental or consequential damage including direct

or indirect labor, repair, medical, or legal expense in any way

attributable to the use of any AeroConversions, Inc. product

or to the delay or inconvenience caused by the necessity of

replacing or repairing any such item.

Engine Monitoring Instrumentation

Sonex Aircraft LLC requires the use of a the following

cockpit-installed engine monitoring instruments in every

engine installation: oil pressure, oil temperature, cylinder

head temperature (1 minimum), and exhaust gas temperature

(1 minimum). Failure to properly monitor your engine may

result in severe engine damage which is not covered under this

limited warranty.

Not TSO'd for Certied Aircraft

AeroVee Engine Kit Documentation

This manual is your primary document for the assembly and

operation of your Experimental AeroVee Engine Kit. The in-

cluded assembly DVD is an additional aide, but when there is

a discrepancy between this manual and the DVD, the informa-

tion in this manual takes precedence.

The manuals provided with the AeroVee kit are important

documents and should be kept with your aircraft's documents.

Keep Your Packing Lists

The packing list provided with each AeroVee kit lists the

specic parts provided for that specic engine. Please refer-

ence your packing list for correct part numbers when ordering

maintenance and repair parts for your particular engine.

In addition to the packing list secured to the outside of the

engine kit boxes, a duplicate packing list has been attached to

the back of the physical manual supplied with that engine.

Copies of (most) packing lists are archived by Sonex Aircraft

and you may request an electronic (PDF) copy. To get a copy,

provide evidence you own the engine for which you are re-

questing the original packing list as well as the engine's serial

number.

Engine Serial Number

The engine's serial number is stamped on the rear of the acces-

sory plate, above the starter. It is also recorded on your pack-

ing list. Record your engine's serial number below.

Engine Serial Number

Stamped on aft side of Accessory Plate, above the starter

AeroVee 2.1 Rev Z. 01/14/2015

ASSEMBLY/SERVICE RESOURCES

AeroConversions Resources

AeroConversions continually improves and monitors its prod-

ucts. It is in your best interest to stay abreast of these improve-

ments and implement them as needed.

AeroConversions Website

AeroConversions, Inc. maintains a website which is continu-

ously updated. Perhaps the most important part of the website

for an AeroVee builder/operator is the Service Bulletin sec-

tion. You are encouraged to periodically check for Service

Bulletins which may affect the performance of your AeroVee

engine.

The AeroConversion website is aeroconversions.com

AeroVee Internet Discussion Group

AeroConversions operates an internet discussion group which

is open to all owners and enthusiast of the AeroVee Engine

Kit. Joining this list will get you in touch with other engine

owners and is an additional form of mass-communication

between AeroConversions, Inc. and its customers.

Information on joining this list is located on the

AeroConversions website at aeroconversions.com.

AeroConversions Tech Support

AeroVee owners can receive individual tech support by email

or phone. We encourage you to contact us via email rst, as

this allows us the opportunity to formulate a clear, concise

answer to your question.

The email address is [email protected]

AeroConversions' Service Bulletins

AeroConversions, Inc. is committed to providing quality

products. We do this through the constant improvement of

our AeroVee Engine Kit, and also by identifying parts or

procedures which we feel require the attention of the existing

AeroVee Engine Kit eet.

When we identify parts or procedures which we feel require

the attention of AeroVee owners, we issue a Service Bulletin.

Required Service Bulletins

A Required Service Bulletin, as the name implies, must be

complied with. It may be a part or a procedure which we feel

must be corrected for the continued use of your engine.

Upon compliance of the Required Service Bulletin, an entry

must be made in your engine log book.

Required Service Bulletins are posted on the AeroConversions

website, announced on the AeroVee Internet Discussion

Group, and mailed to the address of record of each AeroVee

Engine Kit owner. It is your responsibility to keep us informed

of any address or engine ownership changes, and to check the

AeroConversions website for Required Service Bulletins.

Optional Service Bulletins

An optional Service Bulletin is issue when we identify an area

which we feel will contribute signicantly to the reliability/

longevity of the AeroVee engine. Optional Service Bulletins

need not be complied with but we strongly encourage all

AeroVee owners to implement the suggested change/upgrade.

Upon compliance of the Optional Service Bulletin, an entry

must be made in your engine log book.

Optional Service Bulletins are posted on the AeroConversions

website and announced on the AeroVee Internet Discussion

Group. It is your responsibility to check the AeroConversions

website for Optional Service Bulletins.

Keep Your Packing Lists

The packing list provided with each AeroVee kit lists the

specic parts provided for that specic engine. Please refer-

ence your packing list for correct part numbers when ordering

maintenance and repair parts for your particular engine.

In addition to the packing list secured to the outside of the

engine kit boxes, a duplicate packing list has been attached to

the back of the physical manual supplied with that engine.

Copies of (most) packing lists are archived by Sonex Aircraft

and you may request an electronic (PDF) copy. To get a copy,

provide evidence you own the engine for which you are re-

questing the original packing list as well as the engine's serial

number.

Additional Resources

There are many books, magazines, and videos available for

the assembly, maintenance, and operation of "Type 1"-based

engines. We highly recommend "How to Rebuild Your

Volkswagen Air-Cooled Engine" by Tom Wilson (ISBN 978-

0-89586-225-9).

AeroVee 2.1 Rev Z. 01/14/2015

30.00"

20.0625"

21.875"

w/ optional

air cleaner

18.875"

24.25"

4.875"

Prop Hub Bolt Pattern

9/16" Dia. Drive Lug Hole - Typical 6 places

5" O.D.

Drive Lugs Centered on 4" Dia. Bolt Circle

Weights and Dimensions:

Weight (Less Oil and Exhaust):

with Standard Pistons and Barrels .........................160 lbs.

Length ..........................................................................24.25”

Width ................................................................................30”

Height ......................................................................20.0625”

SPECIFICATIONS

4.8" 4.8"

5.55"

Mount Dimensions (Viewed from behind)

See Page 40 for Motor Mount Pin Detail

AeroVee 2.1 Rev Z. 01/14/2015

SPECIFICATIONS

General Specications (Subject to change without notice)

Power and Displacement:

HP @ 3400 RPM ..........................................................80 HP

Static RPM @ WOT (with correct propeller) ...... 3000 RPM

Bore ............................................................................. 92mm

Stroke .......................................................................... 82mm

Displacement .............................................................. 2180cc

Compression Ratios (Builder Adjustable):

7.0:1 For use with automotive gasoline with a posted

(R+M)/2 of 90 or greater conforming with ASTM D 4814.

8.0:1 For aviation gasoline 91/98 minimum grade con-

forming to ASTM D 910

Ignition System:

Firing Order ........................................................... See Photo

Spark Plugs ........................................ Autolite 4163 or equal

Spark Plug Gap:

Top Plugs ....................................................................018”

Bottom Plugs ..............................................................032”

Timing:

Primary Ignition (Magnatrons) ........... Fixed @ 28o BTDC

Secondary Ignition (Electronic) ......................... 28o BTDC

Ignition Module Gap (Primary Ignition) .............. .010-.014”

Cooling and Lubrication:

Primary Cooling .............................................................. Air

Secondary Cooling ........................................................... Oil

Oil Capacity .......................................................2.75 US Qts.

Oil Type ............ See "Engine Oil" section for approved oils.

Fuel System:

Throttle Body .................... AeroInjector, ACV-C07S, 32mm

Approved Fuels:

7.0:1 Compression: Automotive gasoline with a posted

(R+M)/2 of 90 or greater conforming with ASTM D 4814.

8.0:1 Compression: Aviation gasoline 91/98 minimum

grade conforming to ASTM D 910.

Electrical System:

Battery Required (minimum) ......................... 12v @ 20 amp

Starter ......................................................................... Geared

Alternator....................................................................20 amp

Propeller Drive:

Propeller Drive ....................................................Direct (1:1)

Prop Bolt Pattern .......... 6 holes, 9/16" dia., on 4" dia. center

Prop Drive Bushings ......................... 9/16" dia. x 7/16” long

Valve Setting:

Valve Setting (cold) .......................................... 006" to .008"

Operating Limitations (Subject to change without notice)

Idle RPM .........................................................700-900 RPM

Cruise RPM ............................................. 3200 +/- 200 RPM

Maximum RPM ...................................................4,000 RPM

Oil Temp. - Min. ..........................................................160o F

Oil Temp. - Max. ........................................................ 230o F

Oil Pressure - Min. ..................... 10 PSI (hot oil, idle RPM)

Oil Pressure - Max. ...................................................100 PSI

Oil Pressure@ Cruise ............................................ 40-50 PSI

CHT @ Cruise .....................................................350o-375o F

CHT @ Climb (5min.) ................................................ 420o F

CHT Max. .................................................................... 450o F

EGT Max. .................................................................. 1400o F

Cylinder Identication, Engine Orientation,

and Firing Order

Cylinder Identication

For assembly and maintenance, the AeroVee uses the cylinder

identication numbers shown below.

Engine Orientation

When referencing the location / orientation of items on the

engine, "Front", "Back", "Left", and "Right" are used as if the

engine is installed in a tractor conguration and viewed from

behind the engine, as shown below.

Firing Order

The AeroVee has a "wasted spark" ignition system which al-

lows the spark plugs to re on non-combustion strokes as well

as combustion strokes. The arrows in this diagram illustrate

the order of combustion.

Front

Back

Left Right

CYLINDER NUMBERING, FIRING ORDER,

and ENGINE ORIENTATION

AeroVee 2.1 Rev Z. 01/14/2015

BEFORE YOU BEGIN...

Protect Yourself

Always wear safety glasses

When using paint and chemicals, work in a well ventilated

room and wear appropriate protective gear (gloves, mask,

etc.).

The use of compressed air to clean parts is not recommended.

Compressed air can send debris ying at great speed and cause

serious injury.

Do not use ammable liquids near open ignition sources such

as water heaters, furnaces, electric motors, etc.

Read, Understand, and Follow

the Instructions

Read through each procedure before performing the individual

steps.

Make sure you have the appropriate tools, parts, and consum-

ables on hand. Some procedures cannot be interrupted while

you track down that forgotten tool.

Photo References in this Manual

Photos in this manual are included to illustrate specic steps

and may not accurately illustrate what an engine looks like

during an actual build-up. Do not add or remove parts based

on the photographs in this manual. The step-by-step instruc-

tions are your only guide for adding or removing parts during

engine assembly.

Work Cleanly

Parts must be thoroughly cleaned with Mineral Spirits and in

many cases, lubricated, before assembly. Remove rust-inhibit-

ing coatings from each part.

The engine case and cylinder heads must be carefully cleaned

and inspected to remove any metal chips which may remain

from the machining process.

Work Smartly

Parts should never be forced into position. If excess effort

seems to be needed to assemble parts, STOP and investigate

the problem.

NEVER apply concentrated heat (such as with a torch) to

assemble or disassemble parts. Excess heat will damage parts

and result in a potentially dangerous engine installation.

Part Numbers and Packing Lists

The packing list provided with each AeroVee kit lists the

specic parts provided for that specic engine. Please refer-

ence your packing list for correct part numbers when ordering

maintenance and repair parts for your particular engine.

In addition to the packing list secured to the outside of the

engine kit boxes, a duplicate packing list has been attached to

the back of the physical manual supplied with that engine.

Copies of (most) packing lists are archived by Sonex Aircraft

and you may request an electronic (PDF) copy. To get a copy,

provide evidence you own the engine for which you are re-

questing the original packing list as well as the engine's serial

number.

AeroConversions reserves the right to supply compatible,

alternative replacement parts for any part of the core engine or

conversion package. Such parts may appear different than the

part originally provided in the kit or depicted in the manual,

and may bear a different part number, but will be functionally

identical or superior to the original kit-supplied component.

A Successful, Reliable Engine Installation Begins Here.

The use of compressed air to clean parts is not recommended.

Compressed air can send debris ying at great speed and

cause serious injury, as well as drive the debris deeper into

crevasses.

AeroVee 2.1 Rev Z. 01/14/2015

CRANKSHAFT ASSEMBLY

Tools Required:

__ Oven Heated to 400 degrees F.

__ Heat-proof Gloves

__ White Lithium Grease

__ 1/2” Impact Wrench with 30MM Socket

__ Locktite #242

__ Block of Wood

__ Hammer or Mallet

__ Torque wrench (80 ft. lbs. capacity)

Parts Required:

__ Prop Hub, ACV-H01-16

__ Prop Hub Bushing and Washer, ACV-H01-17

__ Crankshaft, ACV-P01-98

__ Oil Slinger, ACV-P01-101

__ #1 and #2 Bearings from Main Bearing Set, ACV-P01-57

Note: Bearing #1 is the small cylindrical bearing, Bearing #2

is the large cylindrical bearing without anges.

__ Retaining Ring, ACV-P01-64

__ Forward Woodruff Key, ACV-P01-99

__ Aft Woodruff Key, ACV-P01-104

__ Crank Timing Gear, ACV-P01-62

__ Bolt, ACV-Z01-74

Preparation:

__ 1. Inspect the bore of the Crank Timing Gear for burrs. If

necessary, lightly polish it with ne emery cloth.

__ 2. Thoroughly clean all parts with Mineral Spirits.

__ 3. Remove the four (4) hex plugs from the crankshaft and

thoroughly clean the crankshaft with Mineral Spirits.

Re-install the hex plugs with Locktite #242.

__ 4. Test t the prop hub. The prop hub should NOT slide

onto the crankshaft.

__ 5. Place the cleaned crankshaft in a freezer at least 12

hours prior to assembly.

__ 6. Heat an oven to 450o F. Place the crank timing gear and

prop hub in the oven and heat for 60 minutes.

__7. Apply an even coat of white lithium grease to the inside

surface of bearing #1 and bearing #2 from the Main

Bearing Set.

Assembly Instructions:

__ 1. Install the Aft Woodruff

Key into the crank-

shaft. Make sure it is

fully seated.

__ 2. Slide bearing #2 (with

an even coat of white

lithium grease applied

to the inside surface)

onto the crankshaft

with the machined

dot (arrow in photo)

toward the crankshaft's

counter-weight.

IMPORTANT. Perform steps 3 through 10 near the oven.

Once the parts are removed from the oven, work quickly

but carefully to assemble the crankshaft. DO NOT

FORCE PARTS ONTO THE CRANKSHAFT.

If a part does not go into place on the crankshaft, STOP.

Do not force it on and do not try to remove it. Contact

Sonex Aircraft LLC before continuing.

Note: If you have the optional pre-assembled crank shaft (part

number ACV-H01-20), skip to Step 10.

AeroVee 2.1 Rev Z. 01/14/2015

CRANKSHAFT ASSEMBLY

__ 4. Install the Retaining

Ring in the groove in

the crank.

__ 5. Enlarge the oil supply

hole in bearing #1 by

updrilling it with a #30

drill bit. Remove any

burrs which may occur

while drilling.

6 & 7

__ 6. Slide bearing #1 (with

an even coat of white

lithium grease applied

to the inside surface)

onto the crankshaft

with the machined dot

(arrow in photo) to-

ward the retaining ring.

__9. Align the keyway of the Prop Hub with the forward

woodruff key installed in the crankshaft and tap the

prop hub into place using a mallet and block of wood.

The prop hub must be tight against the oil slinger.

__10. After the prop hub cools to room temperature, remove

the bolt (ACV-Z01-74), apply Locktite 242 to its

threads, and re-install. Torque the bolt to 80 ft.-lbs.

__ 3. Install the Timing Gear

with the two machined

dots (arrow in photo)

facing away from bear-

ing #2.

Immediately install

Prop Hub Bushing

and Washer and Bolt

(ACV-Z01-74). Use an

impact wrench to tight-

en the bolt and push the

prop hub against the oil

slinger.

__ 7. Slide the Oil Slinger

onto the crankshaft

with the curved

(concave) side of the

slinger facing the end

of the crankshaft.

__8. Install the Forward

Woodruff Key into the

crankshaft.

AeroVee 2.1 Rev Z. 01/14/2015

CAM ASSEMBLY

Tools Required:

__ Socket Wrench

__ 13mm Socket

__ Torque Wrench (20 ft.-lbs. capacity)

__ "Red" Locktite (High Strength Threadlocker)

Parts Required:

__ Cam Gear, ACV-P01-49

__ Cam Shaft (w/ hardware), ACV-P01-72

Assembly Instructions:

Note: The Assembly Lube provided with the cam gear will be

used to lubricate the valve lifters in a later operation. Do not

lubricate the cam shaft bolts as instructed on the assembly lube

package included with the cam shaft.

Note: Cam shafts are supplied with varying hardware, all of

which is acceptable. Use the hardware supplied with the cam

to attach the cam gear. This may include either:

Cam Bolts with integral lock washers.

Cam bolts and wavy spring washers.

Cam bolts and tab lock washers.

Note: While not common, slight interference between the cam

and the connecting rods does occasionally occur. One cause of

this interference is a raised edge around the numbers stamped

in the shaft of the cam. Lightly polishing these numbers will

remove the raised edge and eliminate a possible source of

interference.

A raised edge around the stamped numbers on the cam can

sometimes cause interference with the connecting rods.

__1. Align the machined dot

on the face of the Cam

Gear (arrow in photo)

with the slot in the

Cam Shaft. Apply Red

Locktite to the bolts

and install the bolts and

washers (if provided).

__2. Torque the bolts to 20

ft-lbs.

__3. If tabbed washers were

provided with your cam

shaft, bend the tabs

against the bolt heads

with a at-blade screw-

driver.

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