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Zenith CruZer & Sonex Logs
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Date: 11-20-2010
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Number of Hours: 6.10
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Manual Reference: aerovee
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Brief Description: Mate Case / Install Cylinders / Install R Head
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Big Day. Lots of accomplishment, lots of frustration. Had a lot of help from #2 son James; with all this going on, no way could I have done this by myself.
Started off with mating the case halves. Applied Loctite 518 flange sealer thinly to the left case half. No studs on that side, so it makes it easier. Installed cam plug. Torqued all 21 case bolts - the 6 main bearing studs, 2 cam studs, 10 case studs, and 3 separate bolts.
Next, checked deck height on all 4 cylinders, even though we only had to check on one after re-reading the plans. First, you remove the piston from the cylinder, and pull off one compression ring to check the end gap. All were within spec of .012-.022, most being around .016 gap. Reinstalled rings, used the ring compressor to install the pistons back into the cylinders. Checked deck height. The deck heigh was -.010 to .016, which called for a .090 cylinder shim to establish an 8-1 compression ratio. Removed cylinders to install the cylinder shims. Installed one wrist pin snapring in each piston.
Installed right side cylinders, and decided to install the head in order to torque-down the cylinder spacers. Discovered that all of the studs were too long - interfered with the rocker arm shaft and the intake manifold. Should have checked earlier - other builders have noted it. Removed approximately 3/8" from all 6 studs.
Reinstalled head and torqued to the first increment of 10 ft-lbs. Discovered the pushrod tubes were just a bit too short. Removed head yet again. Stretched the tubes, reinstalled head, and torqued to initial spec of 10 lbs and then final of 18 ft-lbs. Different torque patterns are used for initial and final.
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Torqueing Case Halves
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Checking Deck Height
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Installed Right Head
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