Backcountry Pilot • Lycoming O-540 making metal+2012 Annual update

Lycoming O-540 making metal+2012 Annual update

Lycoming, Continental, Hartzell, McCauley, or any broad spectrum drive system component used on multiple type.
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Re: Lycoming O-540 making metal.

Littlecub wrote:
The plan is to get it to the engine shop before I leave for Africa......

....I fly over some nasty terrain, I don't need a half ass engine.



Sooo, Which engine shop are you using?.....
Like everything else being done-there are good ones (shops), bad ones, and ones that fall somewhere in the middle (most).
With that being said/true, there are an amazingly few sudden catastrophic failures-for all the many piston aircraft engines plying the sky both day and night. We complain about WW2 technology, but when you combine it with the evolving/improving metallurgy that has happened since then we do have exceptional reliability when we 'touch all the bases'.....
I know many times I look at the rugged terrain passing beneath me and am very appreciative/thankful for that reliability. [-o<
lc


We have a good one right at my home base. Premier Aircraft Engines. I here nothing but good talk about them.

Cheers...Rob
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Re: Lycoming O-540 making metal.

Sorry Charley, Tried to find a frowning Charley Tuna this is the best I can do :cry:

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Just glad you found it this way instead or readin about you.
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Re: Lycoming O-540 making metal.

Rob, doing it now might be a lot cheaper than doing it later. You going hunting in Africa? Good Luck
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Re: Lycoming O-540 making metal.

Jaerl wrote:Rob, doing it now might be a lot cheaper than doing it later. You going hunting in Africa? Good Luck

Hey Jerry, shooting animals with my camera. You are no doubt right on the money part of my problem. Plus when the cam goes flat if that turns out to be the problem, it will be right before some big trip I don't want to miss.

Cheers...Rob
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Re: Lycoming O-540 making metal.

Have fun down there and send lots of Pics!
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Re: Lycoming O-540 making metal.

Bum deal Rob-hate to hear that, but at least you caught it before its something way worse.
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Re: Lycoming O-540 making metal.

Sorry to hear but it'll be good to know its solved in the end. That plane brings you WAY too much fun to not do this! :mrgreen: Then, when it's all back and flying, I need to come spend a few days over your way and play!
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Re: Lycoming O-540 making metal.

Littlecub wrote:...With that being said/true, there are an amazingly few sudden catastrophic failures-for all the many piston aircraft engines plying the sky both day and night. We complain about WW2 technology, but when you combine it with the evolving/improving metallurgy that has happened since then we do have exceptional reliability when we 'touch all the bases'.....


While rare, catastrophic failures do occur. I had a C-145 connecting rod break in flight- pretty exciting for a couple minutes but it turned into a non-event as I was able to limp to a nearby airport. A friend of mine had the cam/followers start coming apart in his O-320 mid-flight. Oil temp going up/oil pressure going down tipped him off, he was able to make it to a nearby airport where he discovered the oil screen clogged. Screen was clear & oil was OK at the previous change about 20 hours prior. Apparently once you get through the hardened material on the cam & followers, wear accelerates & metal starts coming off FAST.
Good luck Rob, hope you get through this with your wallet relatively intact.
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Re: Lycoming O-540 making metal.

....... we do have exceptional reliability when we 'touch all the bases'.....


We do have 'failures'..... And some of those can be attributed to 'missed bases'.......
There are a LOT of very important steps in making the parts of just the right combination of metals, 'treating' the metal appropriately(frequently both before and after a part is made), and then proper assembly of those parts- whether OEM or rebuilder.....
And yet, yes we do have (rare) catastrophic failures.

But nothing like 'the good old days' of yesteryear...... =D>
lc



Engine/equipment abuse by pilots is a whole 'nother topic! [-X [-X
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Re: Lycoming O-540 making metal.

Been tearing it down the last 3 hours. I think we may have found it. Bent pushrod and tube. Anyone seen this before. Does it hurt the cam and tappet? We are pulling the cylinders now to look at the cam. PLEASE CAM BE OK PLEASE!!!!!!!!!!

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Re: Lycoming O-540 making metal.

Depends on why it bent and was it exerting a side load on the lifter in the bore, I have my fingers crossed for you and hoping that all is well from there down! [-o<
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Re: Lycoming O-540 making metal.

Well, worst case. It is all toast! Top gone, cam gone, 1000 hr and gone. Really bummed :(
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Re: Lycoming O-540 making metal.

OregonMaule wrote:Well, worst case. It is all toast! Top gone, cam gone, 1000 hr and gone. Really bummed :(


Now that REALLY., REALLY sucks. :( :( :( :( .. Hard to believe that motor took a dive in just 1000 hours.. [-X [-X [-X

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Re: Lycoming O-540 making metal.

Stuck Valve or Hydrolock?

Used to have an old Slant 6 Dodge truck motor..bent several push rods from stuck valves.
Hydrolocked a 355 CID Chev racing motor..bent pushrods and other things.
Hope you get through this withouit costing you an arm and leg. [-o< That was fast!!
Better to find out now than when it became toast climbing out of Dewey Moore!!
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Re: Lycoming O-540 making metal.

Sorry to hear that Rob.... Always sucks to have a motor do that before TBO... :(

Worst I have had is the re-ground cam we put in our 0-360 for the Cherokee lasted 10 hours before we had to split the case and replace it.... :cry:

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Re: Lycoming O-540 making metal.

Rob, Sorry to hear that, Have you figured out what bent the tube and push rod?? That rotation of the can on the lifter and push rod sure did work hard to ream all that metal of the push rod!!
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Re: Lycoming O-540 making metal.

OregonMaule wrote:Well, worst case. It is all toast! Top gone, cam gone, 1000 hr and gone. Really bummed :(


Rob what do you mean top gone? Understand cam but top of what? Sorry for your loss, it can be fixed.
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Re: Lycoming O-540 making metal.

ah dammit! :cry:
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Re: Lycoming O-540 making metal.

OregonMaule wrote:Well, worst case. It is all toast! Top gone, cam gone, 1000 hr and gone. Really bummed :(


But you're still here, man. Might not feel very lucky, but a lot of guys have found out the hard way.
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Re: Lycoming O-540 making metal.

In 2001 my M7 had a prop strike.The engine went to Lycoming for the new crank and strike inspection, then sat from 2001 to 2006 with 30 minutes on it because the owner was afraid to fly it.

I got it and it has run perfect ever since. Then oil analysis tipped me that something was not right. 90% of the guys here and on the Maule site said open it, so I did and the rest as they say history.

I would highly discourage anyone from buying a plane with an airplane with an engine that set not pickled. If not pickled negotiate a tear down inspection. If you don't you are gambling. I gambled and lost.

Good day
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