Engine

Lycoming IO-540-C4B5 Serial #: L-15798-48 Parallel valve, narrow deck engine core as it arrived from Wentworth Aviation in Minnesota. Ready to disassemble.

Here's my Flickr photo gallery. I'll move pics over here when topics require.

Rebuild

I have rebuilt this core engine after it suffered a prop strike during a gear-up landing in a Piper Aztec in 2014. Nearly every component of the bottom end was in good serviceable condition save for the crankshaft, which was cranked at an oil cross tube. Replacement crankshaft is from a O-540-F1A5 out of a Robinson R-44.

This has been the most thorough and complete task of the Bearhawk build thus far.

To do:

• Bolt cylinders on - DONE
• Install oil drain-back nipples in case - DONE
• Install idler gears - DONE
• Determine which gears are being omitted from accessory case - DONE
• Clean pushrods in Graham's parts washer - DONE
• Powdercoat intake tube clamps or find machined new ones - DONE
• Cut new intake pipe hose into 1.75-2.00" sections
• Constant pressure clamp pliers
• Rocker covers, gaskets, hardware - INSTALLED
• Intercylinder baffles - INSTALLED

Ignition and injection

Plan is to use FlyEFII System32.

Reverting back to original idea of using Airflow Performance fuel injection, a modern version of Lycoming RSA style. EFII is just too much wiring.

To do:

• Fuel valve mount bracket placement.
• Fuel line routing and design

Lycoming resources

File name	Type	Size
Lycoming overhaul manual	PDF	15.2 MB
IO-540 Parallel Valve Narrow deck IPC	PDF	7.6 MB