Scott & Tanya Card RV9A build log (N4822C)

The cylinder replacement operation is complete. It took us about a week and 35 hours. Tanya helped a lot with the re-assembly process. The easiest and quickest part was actually removing the old cylinders and installing the new ones. Everything else took most of the time. We did a couple of test runs on the ramp. The engine started very easily and seemed to run fine. Now we’re ready for a test flight and break-in.

Well, what can I say, it isn’t rocket science. I removed all of the original cylinders and installed the new assemblies. The fully prepared assemblies make it very easy. The valves are already installed and the piston is already in the cylinder. Lube things up, install the base o-ring, slide the piston pin in with caps, and install the base nuts. Next up is to do the pushrod dance for rocker/valve clearance. Of course I’m working from THE overhaul manual.

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As we started discussing the replacement of the cylinders subject to the AD, Scott made a passing comment that they were my anniversary present. While working with Joe at ECI, I relayed this comment and jokingly said he needed to be sure to put bows on them for me. Well, he did…

The oil analysis reports show some tin so the cylinders themselves must contain some (10 Year Traditional Anniversary Gift), and they are going on an aluminum airplane (10 Year Modern). I guess he has it covered.

Today I started the dis-assembly to replace the cylinders. While I was at the airport, the new cylinders arrived at Tanya’s office and the cylinder base nut wrenches that I ordered were delivered to the house. Good timing. I did about 5.5 hours of work and got all of the baffles removed, exhaust off, intake tubes off, spark plugs pulled, manifold pressure and primer fittings removed, head oil drain tubes removed, inter-cylinder baffles removed, oil drained, rockers, pushrods, hydraulic lifters, and pushrod tubes removed. I have everything carefully organized so it goes back in the same place. I brought the baffles home for Tanya to clean up. I’m now ready to begin removing cylinders.