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  #21  
Old 03-04-2017, 05:26 PM
Norcalrv7 Norcalrv7 is offline
 
Join Date: Jan 2015
Location: McKinleyville CA
Posts: 183
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Quote:
Originally Posted by Walt View Post
That nose seems awfully light!

My own 7A numbers are MLG 444/442, NLG 302, 1188 total (chubby girl I know).
Other examples of 7A's with CS props I've weighed:
439/436/292
432/444/309
428/425/306
Interesting. My girlfriend already scraped out all of the sound deadening behind the seats. (She's a keeper) Maybe I'll look harder for a hidden piece of lead. It would be interesting to see the weight difference of a painted vs non painted tail.

Caleb
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Flying RV-7A With SDS Electronic fuel injection
ATP CFI A&P
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  #22  
Old 03-04-2017, 06:10 PM
Norcalrv7 Norcalrv7 is offline
 
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Location: McKinleyville CA
Posts: 183
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This project started when I bought a low time "runner" IO360 from a salvage yard that will go nameless. The plan was to install Ross's EFI components and fly. I decided to disassemble it first before bolting it on. good thing I did. I found 2 broken piston rings, and badly corroded cam. So into the bottom end I went, only to find a scored crankshaft, that had already been ground to minimum undersize. The only thing of value left was the case, which luckily passed inspection at Divco. For a guy in his late 20's, I did the only logical thing. I worked overtime, lived with roommates, and ate lots of ramen noodles to pay for all the new parts. Luckily the airplane was still flying under Subaru power, so It was easy to take my time and save for the parts I wanted. A new crank, cam, sump (forward facing) and 4 new cylinders later, I got to put it all together with the watchful eye of my mentor mechanic. I have rebuilt several car engines, but this was my first Lycoming. Aside from the price tag for the parts, I found it enjoyable and straight forward. Since I can't say I built my RV, I figure the next best thing is to say I built the engine!

2016-03-14 11.37.09 by Caleb Lesher, on Flickr

2016-03-17 14.16.28 by Caleb Lesher, on Flickr

2016-03-18 12.29.07 by Caleb Lesher, on Flickr

2016-04-06 08.32.22 by Caleb Lesher, on Flickr

2016-04-06 14.09.00 by Caleb Lesher, on Flickr

2016-04-11 12.52.00 by Caleb Lesher, on Flickr

2016-04-12 16.03.14 by Caleb Lesher, on Flickr


2016-04-15 13.51.43 by Caleb Lesher, on Flickr
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Flying RV-7A With SDS Electronic fuel injection
ATP CFI A&P
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Last edited by Norcalrv7 : 08-28-2017 at 10:19 AM.
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  #23  
Old 03-04-2017, 09:38 PM
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DanH DanH is offline
 
Join Date: Oct 2005
Location: 08A
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Quote:
Originally Posted by Norcalrv7 View Post
1168 total. 445 left main, 452 right, and 261 on the nose.
Doesn't add up to 1168. Which value needs correction?

Caleb, it's a pleasure to see a nice, clean, well organized engine build.
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  #24  
Old 03-04-2017, 11:16 PM
Norcalrv7 Norcalrv7 is offline
 
Join Date: Jan 2015
Location: McKinleyville CA
Posts: 183
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Quote:
Originally Posted by DanH View Post
Doesn't add up to 1168. Which value needs correction?

Caleb, it's a pleasure to see a nice, clean, well organized engine build.

My mistake, nose is 271 and 452/445. Thank you Dan! I hope it runs as good as it looks.

I decided I'm going to Re-level, weigh, and measure tomorrow. I have accomplished different parts of the procedure at different times with the plane being level/not level. Maybe I'll take the tail fairing off again and look for some extra weight too :-)

Caleb
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ATP CFI A&P
Based at EKA, Northern CA

Last edited by Norcalrv7 : 03-04-2017 at 11:25 PM.
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  #25  
Old 03-05-2017, 12:48 PM
Norcalrv7 Norcalrv7 is offline
 
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Location: McKinleyville CA
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One of the more critical processes with the installation of the SDS EFI system is the hall sensor mounting and signal magnets. Ross sent me everything I needed to lay out and mount the signal magnets on my own. Unfortunately, the Starter ring gear support that came with my engine had the smaller pulley style. The larger is needed for the SDS system I was able to source one with a bad ring gear that I found that it was off of a O320-E2D. The only difference was that it had smaller holes for the crankshaft bushings. I was able to lay out the holes, and ream them to the proper size. One word of caution when using this technique. The 320-E2D (and possibly others) has a differently indexed layout than the IO360 engine. There is one larger hole marked with an "O" that should match the crankshaft. This "O" was in a different position relative to the TDC marks on the original ring gear support.

Modifying the 320 ring gear to fit the 360, and tapping for magnets
2016-04-08 13.22.18 by Caleb Lesher, on Flickr

2016-04-11 10.06.21 by
Caleb Lesher, on Flickr

I have a special container of granddad's safety wire from the 70's that gets used on important things, like the hall sensor mount shown here
20160607_174352 by Caleb Lesher, on Flickr

The exiting boxes are starting to arrive!
20160303_123257 by Caleb Lesher, on Flickr

Cheap meal to save money for more airplane parts :-)

20160705_213003 by Caleb Lesher, on Flickr
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ATP CFI A&P
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Last edited by Norcalrv7 : 08-28-2017 at 10:30 AM.
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  #26  
Old 03-05-2017, 01:02 PM
Norcalrv7 Norcalrv7 is offline
 
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Location: McKinleyville CA
Posts: 183
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I elected to make my own wiring harness for the ECU, so I could route the wires exactly how I wanted them, and also have the personal experience of the wire layout. I used the provided plugs and pins, with adhesive lined heat shrink, and mesh type wire loom. With the proper crimp tool and pins, I found the wiring process enjoyable.

I also switched from my original idea of a loop style fuel rail to the individual lines and fuel block from Ross shown here.

20161112_105303 by Caleb Lesher, on Flickr
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Last edited by Norcalrv7 : 08-28-2017 at 10:22 AM.
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  #27  
Old 03-05-2017, 01:31 PM
Norcalrv7 Norcalrv7 is offline
 
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Location: McKinleyville CA
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While I had the firewall completely torn apart, I had some work behind the panel to complete also. I found a good deal on a 10" HXr efis to replace my 8" model. One thing led to another, and before long I had also purchased a used Garmin 430W to replace my 480, and a Garmin GTX345 transponder with ADS-B in and out. I also added a seconds SL40 COM. It was winter anyway, so why not get it all done now.


I built a custom heater plenum with attachments for the defrost vents to replace the heater core from the Subaru.

14440969_1379667885384278_6218592851467915973_n by Caleb Lesher, on Flickr

I also made a lower panel cover plate to cover all the old switch holes, and to add a propeller control cable.

At this point I was wondering if this was a bad idea.
13731538_1292859554065112_2627549356242851577_n by Caleb Lesher, on Flickr


20161106_214236 by Caleb Lesher, on Flickr

A few months later, and it all works!

20161107_154353 by Caleb Lesher, on Flickr

After:
0823171011 by Caleb Lesher, on Flickr
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Last edited by Norcalrv7 : 08-28-2017 at 10:35 AM.
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  #28  
Old 03-05-2017, 01:51 PM
scsmith scsmith is offline
 
Join Date: Jan 2008
Location: Ashland, OR
Posts: 1,693
Default Induction tube

You will have a very small frictional loss from that length of tubing compared to a larger snorkel. But it probably very small, since, as Ross said, your tube is larger than the throttle body throat.

I am very curious, however, how you got the aluminum tube out after you wrapped it.
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RV-8 N825RV
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WW 200RV
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Hobbs 470 in 8 years
also LS-6-15/18 sailplane
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  #29  
Old 03-05-2017, 02:40 PM
Norcalrv7 Norcalrv7 is offline
 
Join Date: Jan 2015
Location: McKinleyville CA
Posts: 183
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Quote:
Originally Posted by scsmith View Post
You will have a very small frictional loss from that length of tubing compared to a larger snorkel. But it probably very small, since, as Ross said, your tube is larger than the throttle body throat.

I am very curious, however, how you got the aluminum tube out after you wrapped it.
1 ply of fiberglass, then I cut it lengthwise, peeled it off, and ca glued it back together before adding 2nd layer

Caleb
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ATP CFI A&P
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  #30  
Old 03-05-2017, 02:53 PM
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rv6ejguy rv6ejguy is offline
 
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Location: Calgary, Canada
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The photos of your journey are great. Appreciate you posting them here. Nice clean layout on every facet. Might help others following in your footsteps.
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Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW- 416.6 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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