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10-05-03

Corvair Assembly !!!! - PLENTY OF PICS BELOW!

15.0

engine

DETAIL:

Today was the day I have been waiting for !  After over a year of gathering Corvair parts, having the crank reground, head/valve jobs, LOTS of orders from Larry's and Clarks, countless nights wondering how I will setup my starter, carb, exhaust, etc....  I have finally begun assembly of the engine.

A recap of the basic info:

A 1965 110hp 164 cu. in. Corvair air cooled 6 cylinder engine. Converted for use in an aircraft following William Wynne's specifications/plans.

OT-10 camshaft, Forged TRW pistons and bored/honed cylinders (.020 over), ARP rod bolts, reworked balanced rods, new valves, guides, springs, machined intake plenums with welded 90 degree intake pipes, Nissan Sentra flexplate and starter, dual points distributor, new oil and fuel pumps, reground crank with safety shaft mod, William Wynne prop hub, oil pan, safety shaft & hybrid studs, homemade CNC'd finned top cover, 32mm AeroCarb, 66x28 Tennessee Propellers wood prop, and probably some other stuff I'm forgetting.

After nearly a year of saving a little $$ and then buying parts then saving a little more $$ and buying parts I have finally got to the point of assembly.

There are LOTS and LOTS of pics below. Scroll down to see them all.  They were all taken last night, 10-04-03 and today 10-05-03.  The shots showing the engine "totally" assembled are just temporary shots as I have only completed the case assembly.  The pistons, cylinders, heads, etc will be installed this week.

MANY THANKS to all of the helpful guys on the CorvAircraft email list who have provided excellent input throughout this process.

Click here to see a side by side "before" and "after" of my engine.

What the engine looks like as of now... cylinders and head are temporarily
installed just to see what this thing looks like.

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Cleaning the case halves

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Oil passage plug removed so a gun cleaning brush can be run through.

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Q-tips used for oil passages in bearing surfaces. VERY important to make
sure no cotton fibers get stuck in there.... I blew mine
thoroughly with compressed air afterwards.

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Cotton swatches used to clean the oil passages.  Look at all the crud on those!

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Masking off the case/studs for painting - What a pain in the ASS!

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Masking the cylinders for high temp 1000 degree F stove paint

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Simple wood jig screwed to table to hold the case in position for assembly.

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Getting ready to drop the crank in

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Alignment of the cam/crank timing marks

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Moroso Moly-Lube on cam lobes

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Assembled case!

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Close-up of my intake plenum modification