I purchased an engine core and have had it overhauled and bought six new ECI cylinder assemblies for my RV-10 IO-540-C4B5 engine. I expect to have about $20,000.00 invested in my engine when complted but I will have basically a new engine as almost everything has been overhauled to new specs or replaced with all new five year guaranteed cylinder assemblies.
There are four basic processes to look at, in buying a core and rebuilding an Engine.
1. Locating a really good IA or A&P locally to work with you in getting an engine overhauled. If you fail here everything else is hopeless. You should be able to get someone to overhaul the engine for about $750.00 labor cost, depending on location. East or West coast is likely to be higher. Check with your local EAA tech counsler.
2. Obtain a core from a reputable company who will give you a WRITTEN guarantee that the crankshaft will overhaul to FAA minimiums. DO NOT let someone sell you an engine core that has been already broken down, as they might steal all the good parts and give you a box of worthless parts. Also make sure your IA or A&P is involved in determining if all of the core componants and accessorys are present. Ideally you want to buy a core removed from a flying airplane for a new engine replacement with a complete set of engine logs.
3. Breaking down the core and sending off the major components for overhaul. Major components include the Case, Crankshaft and counterweights, and Camshaft.
4. Replacing as required, or having overhauled, and/or inspected, and/or maga flexed, the minor components of the core.
FYI: The following is an almost completed list of my engine overhaul parts(part numbers not guaranteed correct as I depend on my IA):
RUSS DAVES? IO-540-C4B5 ENGINE PARTS
1 IO-540-C4B5 Crankcase, serial #948 - L6622 -48 Overhauled by Crankcase Services, Inc., Sand Springs, OK. Narrow Deck -48
1 IO-540-C4B5 Crankshaft M003- S143390-1 - Overhauled and returned to service via Yellow Tag (Ground Rods & Mains M003, Nitrating, Cad Plate and Baked, reassembled and installed counterweights, and returned to service in accordance with current FAA regulations) by Aircraft Specialities, Tulsa Oklahoma.
2 Lycoming Counterweights & Bushings Model 72801? S142528-3 & S143417-3 - Repaired and Inspected in accordance with current FAA regulations and approved for return to service by Aircraft Specialities, Tulsa Oklahoma, mounted on crankshaft.
1 Crankshaft Gear #AEL19647
1 Crankshaft Gear Bolt
1 IO-540-C4B5 Camshaft with Intergral Gears mounted #76148 (Governor/Drive Gear) - Reconditioned, Certified, and returned to service via Yellow Tag (Reground lobes to approved specifications and Magna fluxed by Aircraft Engine & Accessory Company, Inc.
6 Connecting Rods (New) purchased from ECI
#AEL11750 with bolts & nuts installed.
12 Lifters Model 72877 - Inspected Visually, Dimensionally, and by Magnetic Particle Method, Wear Faces were reground to FAA approved design Specifications by Aircraft Specialties Services, Tulsa Oklahoma
12 Hyd Units Model 78290 - Cleaned, Inspected and Overhauled in Acc. W/ Aircraft Specialties Procedure 99-001 by Aircraft Specialties Services, Tulsa Oklahoma
12 Hyd Unit Socket Ends Service and Inspected
1 IO-540-C4B5 Accessory Case ? Refurbished and Inspected
1 Sump - Refurbished and Inspected
6 Rocker Arms #74636 Reconditioned, certified, and returned to service via Yellow Tag by Aircraft Engine & Accessory Company, Inc.
6 Rocker Arms #69444 Reconditioned, certified, and returned to service via Yellow Tag by Aircraft Engine & Accessory Company, Inc.
6 Piston Pins Purchased New from ECI
1 Oil Pump Gear & Body #SL78528
1 Oil Pump Drive Shaft #74641 (Magna fluxed by Porterfield)
1 Oil Pump Ball #SL1028-8 (new)
1 Fuel Pump Plunger #61544 (Magna fluxed by Porterfield)
1 Bendix RSA 5AD1 Fuel Servo - Overhauled and yellow tagged by Southeast Fuel Systems, Inc. With upper and lower gaskets.
6 Fuel Injector Nozzles (New)
6 Fuel Injector Lines - Used, like new
6 Chrome Cylinder Head Covers New from ECI
6 Intake Pipes Inspected and Painted
6 Intake Pipe Clamps Inspected and Painted
12 Push Rods #73436 (Magna fluxed by Porterfield)
12 Push Rod Tubes Inspected and Painted
1 Accessory Drive Gear #71652 (Magna fluxed by Porterfield)
1 Accessory Drive Gear #71668 (Magna fluxed by Porterfield)
1 Vacuum Pump Drive Gear #72974 (Magna fluxed by Porterfield)
1 Hydraulic Pump Drive Gear #72964 (Magna fluxed by Porterfield)
2 Gear Shafts #72246 (Magna fluxed by Porterfield)
1 Governor Drive Shaft #70389 (Magna fluxed by Porterfield)
1 Idler Gear (Governor) #70388 (Magna fluxed by Porterfield)
1 Idler Gear Shaft (Governor) #70384 (Magna fluxed by Porterfield)
1 Tach Drive #76155
1 Sky Tech Starter returned to Sky Tech for Overhaul
1 Oil Dip Stick and Oil Dip Stick Tube
1 Hydraulic Pump Adapter
2 Slick Mags & 2 Mag Drives
1 Wiring Harness
4 Motor Mounts #70456
1 Starter Ring Flywheel
1 Vernitherms
1 Oil Pressure Relief Housing
1 Oil Pressure Regulator
1 Vacuum Pump Drive Adapter
24 Base Nuts
8 Inner Cylinder Baffles
6 Cylinders Assemblies purchased from ECI (Cermanil)
2 Main Front Bearings (New ECI #AEL13884M003)
12 Connecting Rod Bearings (New ECI #AEL13521M003)
6 Main Inner Bearings (New ECI #AEL11021M003)
1 Fuel Pump
1 Gasket Kit