AOPA Pilot Magazine - August 2022 - 62

and radios, including replacement of
worn upper and lower instrument panel
shock mounts and a new paint scheme.
During several flights I had noticed
a significant engine vibration between
1,900 and 2,300 rpm. The most annoying
problem was the tendency for the aircraft
to enter a 20-degree bank to the left when
the controls were neutralized. I decided
to contact my friend, nationally known
'coupe expert Lynn Nelsen, for his experienced
hand at the rigging.
I asked him to give my new baby
the once-over for anything that might
require attention to bring the airplane up
to standards. A careful scan of the logbooks
revealed several extended periods
when the airplane did not fly, along with
sketchy annual inspections and compliance
with airworthiness directives
and service bulletins. He noted that the
engine had been overhauled, not once
but twice, and the control systems were
last lubricated five years ago. Several oil
and exhaust leaks were found, which
could have been attributable to worn piston
rings. The engine had only 500 hours
since major overhaul, but that was 16
years ago. Nelsen pointed out that ring/
piston wear causes excessive blow-by,
creating not only a mess, but also excessive
internal pressure in the engine.
Nelsen's powerplant expert Jeff Biter
came on board to install new rings and
give the engine a thorough inspection.
When the cylinders were removed, he
discovered that at least two of the valve
tappets showed spalling, which could
cause uneven wear on the camshaft, if it
had not already. He said, in addition to
replacing the tappets, the camshaft might
need to be reground or replaced. Biter
split the engine case for a more detailed
inspection, which revealed a host of
problems including two cylinders out of
round and two beyond repair. Time for a
top overhaul.
The following is a partial list of work
accomplished by Nelsen and his son over
the next three months:
* Overhaul nose gear with new bushings,
internal and scissor parts.
* Replace damaged carb heat box, missing
baffles for the oil tank and starter,
baffle clips and springs, a tail pipe
hanger, and a worn exhaust bracket.
* Replace scat tubing, hoses, clamps, and
all nonstandard hardware.
* Detail engine compartment.
* Properly orient fuel pump and install
new fuel lines.
* Replace missing canopy latches.
* Repair cowling, add chafe strips.
* Remove and reinstall engine and
propeller.
While waiting on the engine to be
finished, Nelsen suggested that the prop
should be sent out for inspection and service.
He added I might want to have it
re-pitched as a cruise prop to gain some
extra speed. I thought that would be a
good choice, so off it went to Aircraft
Propeller Works in Auburndale, Florida,
for a makeover.
The day finally came for a series of
test flights during which Nelsen carefully
noted any items that needed tweaking.
Adjustments were made to wing trim,
mixture, and throttle, and then everything
was to his satisfaction. After being
apart for 83 days, Eight Sierra Whiskey
and I finally headed home. We laughed
and sang very loud-all the way. It was a
really good feeling.
The bumpy road to restoring and
updating 818SW took hundreds of hours
over five months. Indeed, there were lots
of unknown expenses and many costly
Equipment upgrades to bring the airplane into the twenty-first century included a Garmin GTR225
com radio; GTX 335 transponder with ADS-B Out; GAE12 encoder; Garmin GDL50 ADS-B In;
Garmin Aera 760 portable GPS; PS Engineering PS3000 intercom; 406 MHz ELT; Stadia ground
proximity detector; sub panel for additional circuit breakers; avionics master switch; LED map light;
dimmer for map, instrument panel, and compass lights; LED landing and taxi lights with pulse
controller; flashing LED beacon; wing tip LED anticollision, position, and nav lights; clock; timer;
outside air temperature gauge; G and voltmeter; 50-amp alternator; lightweight pushbutton starter;
new directional gyro; vertical card compass; cylinder head temperature/exhaust gas temperature
gauge; and sealed battery and battery minder/charger. Prior to purchasing the Aircoupe, a new
leather interior was installed to match the fresh paint on the outside.
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AOPA PILOT / August 2022

AOPA Pilot Magazine - August 2022

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