EJ25 upgrade on SxS

[CLS447]

OK, I finally started looking at the stuff that has drained the bank accounts.

I started by modifying the wooden engine stand & sat the dirty used EJ25 SOHC engine on it.

I then removed the short metric bolts from the end of the crankshaft.

Then I figured out how disassemble the Autoflight gearbox (no instructions included, but simple) for temporary mounting.

1. aluminum adapter bolted on to crank with longer metric bolts(included).
I need a thinner walled socket to torque these bolts. I also need to know the torque values & type of loctite recommended.

2. The ring gear (flywheel?) in place.

3. The rubber thing in place after thin plate. Three large bolts hold this on. I also need the torque specs for these. NEIL ARE YOU LISTENING ?

4. Then the gearbox & mounting plate slips on the two alignment dowls on the bellhousing & is fastened with the included bolts.

One short bolt is included with the starter but I need to know what the top starter hole gets fastened with.

[CLS447]

Here are the pics.......

[CLS447]

I got a prerotator drum from my friend Doug at Air Command. With a little help from the machine shop, she fits nice. 9" drum made to fit the 5/8" drive lugs & the prop flange.

The back plate for the IVO Magnum was bored for 3/4" drive lugs. So I will have the plate drilled & bored between the existing pattern to exactly fit what I have here.

The 6 1/2" bolts that came with the IVO are about an inch too long . I hope that they will take a swap or I will have to buy new ones $$$$$.

I then assembled the prop.....NICE !! I don't believe that I got any instructions with the IVO so I will be calling them about that. I remember Stan talking about their torqueing procedure. ???

[Timchick]

Looking good, Chris.

[CLS447]

That should cover the redrive & prop. That's a start! But there are a ton of other things for me to do.

Some of the small hurdles that I will have to jump.......

Please feel free to offer suggestions . In other words.....HELP !!!!!!!!

1. How to mount this beast.
The EJ25 will need a strong mount. I would like to try & use alot of the stuff that I already have such as the basic bed mount. This engine only has one vertical mounting bolt hole on each side. The other two are at an angle. I think that it will need more than just those 4 bolts!

2. How to run & mount the flex shaft so that it can drive the prerotator. This will be fun! If I can remotely mount the oil filter, it should be a clear shot between the oil pan & the exhaust. That is how I did it with the EA81 but didn't have the oil filter in the way.
This engine appears to have some type of oil cooler under the filter. Is anyone aware of these?

3. I will need an exhaust system. I guess it will be best to wait until everything else is together before I put too much thought into that !

4. Installing & mounting the computer & wiring harness. Don Parham redid the harness & has excellent diagrams included, but the mounting is on me !
Also probably rewiring the whole gyro!

5. Of course the rehang test & subsequent adjustments will also be a blast ! I hope to not have to move my axles for the heavier engine.

6. Air filter assembly ?

7. New plugs & wires.

8. Fuel system. I at least have the pumps.

One thing I do look forward to is throwing that damn protractor in the trash ! One simple twist & the prop pitch is changed. What RPM did you want?

I am sure that I missed a couple million other things but this SxS is my do or die goal in life now. Then I will get an enclosed machine.....MAYBE !

[CLS447]

Thanks Tim! I take joy in believing that I will have enough power,with this engine, to take anyone up....regardless of weight & density altitude.

That EA81 kicks but just not enough. I will probably fly it again in the spring before I do the total tear down. There is plenty to do before I am ready to mount this on. I kinda wished that I had a mule frame for mockup & test runs....hmmm.

[animal]

Looking good Chris! that should fly your baby with no problems at all. looking forward to watching your build progress on this engine upgrade.

[ben]

way to go chris ,

glad to see ya back at it

stan tell him what the delta cams did for your ej25 !! chris, it would be a good time to do it!!

[automan1223]

Chris,

Take your time. Do it right. You have a pocket full of power there. That setup is a bit heavier than your 1.8 but stock should put out a good 50- hp more. I hope your landing gear, airframe is up to it.

I am curious why the 2.5. An efi 2.2 should have plenty of power, but you wont have to worry about it now.

Why wait, get started now.

I guess santa was good this year.

Jonathan

[CLS447]

Well, I'm not screwing around anymore! Everyone that has gone to the 2.5 is overjoyed. Pat Mcnear,Steve Osborn,& all the SH's.

Hopefully I will be able to cruise at 4000 rpm or less. ???

Ben ,changing the cams is the least of my worries right now. That should be easy. I would like to see the difference when I do it.

I will be doing things here that nobody I know of has done.
Drum prerotator with Autoflight gearbox. It's gonna be alot of custom work.

I wished I had Dick Degraw to help me !!!!!!! Maybe even add some jump takeoff !!!!!

[rfi]

Chris,
You will have to move the main gear back around 4 inches if you haven't already done so. I converted Jim DeGaetano's SXS Air Command years ago.

[LARRYEBOYER]

Chris. Good hearing from you. Nice work!!! Your present engine mount looks plenty strong, but you are the best judge of that. Hope you have a super fun cruise. Bon Voyage!!! I look forward to the pics.

[route66]

Chris,
Looks like you have a project on your hands. You asked about the oil cooler at the filter and my conversion had the same. I removed the cooler and replaced it with a Perma-cool sandwich adapter #186 which has fittings to add a remote cooler. The adapter is only 1” and going with a short filter gave me clearance for the engine mounts and exhaust. They have other adapters in case you want to have a remote filter and cooler also. http://www.perma-cool.com/Catalog/Cat_page28.html

Looking at your picture, is there enough room between the intake and prop to route your MAF sensor and air filter to a location which is less turbulent. I had to rotate the manifold to have the intake forward to make mine work. Just a thought.

[CLS447]

Thanks alot Brandon ! I hope to not have to flip my intake. Don Parham said that there would be more wire harness work for that.

Ozzy Russ and others down under have done it this way. So I hope that I can get all that info from them.

Like Larry said we are off for a Carribean Cruise so we will be gone for a while.

But that oil cooler info is great & just the kind of help I will need. I will pick your brain & ask for pictures when we get back.

Did you feel the oil cooler needed to stay on the engine? I don't think all 2.5s have them.

[StanFoster]

Chris: That 2.5 with that redrive...and that Ivo....wow....you are going to love it! You and Shar will have a rocket ship....you better put training wheels on it!


Its nice to see you so enthusiastic about it......its fun to watch your progress.


I just read you asking me about the torquing procedure for the Ivo prop. I kept mine at 65 foot pounds.....and checked it every couple of hours...only took half a minute. I seldom had any of the 6 bolts that needed any tightening,..but maybe just a nudge at 10 hours. Oh...the first few hours are real important as the flanges seat in. Just keep checking the torque to 65 foot pounds the first 15 minutes...then every half hour up to 4-5 hours...then just for your own benefit of the doubt...just check it as often as you want...but they recommend every 10 hours. No more fuss than a half a minute...I probably checked mine too much...but better too much than not enough!

Enjoy that cruise.....you two deserve the best>

Stan