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Zenith CruZer & Sonex Logs
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Date: 1-1-2011
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Number of Hours: 3.50
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Manual Reference: aerovee
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Brief Description: Intake Work / Carb Drilling
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Began by installing and torquing the lower four sparkplugs. Next, installed the CHT probes onto the left cylinder head (right side done 2 days ago...).
Installed the left and right intake elbows. Checked their fit before applying flange sealer - was glad I did. Found an aluminum shaving next to a stud on the left side, and a blob of hardended sealer around a stud on the right side. Both of these kept the elbows from sitting flush on the head. Would have resulted in an intake leak if I didn't notice. Applied flange sealer to the elbows and torqued into place. Next, fitted the rubber hose connectors on each of the elbows. These were a super-bear trying to fit over the elbows. This is tough hose, and does not stretch much. Used silicone spray and some odd body language to get them on.
Next was the intake manifold, and with that the carb. Dug out the carb to check the direction it's supposed to be mounted on the manifold. Then noticed that they suggested installing the air cleaner before attaching to the manifold. Glad I researched this. You must position the cleaner base, use a drill bit thru one of the mounting holes to "mark" the location, then drill thru the carb and tap the hole for an AN3 bolt that holds the cleaner base to the carb (pic 2 below). Noticed that the hole in the carb thru which the mixture cable goes was much smaller than MY cable. Further reading showed that you can up-drill that hole to support the chosen cable, so that was done (7/32").
THEN I moved on to the intake manifold. There were warnings on the manifold and the printed instructions warning the builder to clean out the manifold before installing. There was all kind of thick coagulated oil in there, and of course a bunch of chips. Used mineral spirits and alcohol to attempt to clean out, along with compressed air. STILL had gunk in there. Used the old gun-cleaning method of wrapping some safety wire around a blue shop towel and using that to swab the bore of the manifold. This was done repeatedly until clean.
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Installed intake elbows & connector hose
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Air cleaner mounting hole drilled and tapped
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Mixture Cable Clamp Updrilled
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