Engine Project Complete!

[dstates]

I brought home a used engine back in August of 2023 and it is finally field overhauled, installed and flying!

I purchased a C-145-2 from a gentleman in Michigan who purchased a project 170B (N2693D) from Louisiana and was planning on getting a running engine or putting in a 180hp Lycoming. If I remember right the plane had sat for 10 years after getting this engine installed (originally installed in a Swift), but had never flown. Here is a link to his project, I believe he ended up having to sell the project (https://backcountrypilot.org/forum/cess ... ject-26526). My A&P IA friend and I took our time and got everything sent out and then started the assembly process last summer. Old engine removed in January and first engine run was April 28, 2026 and first flight May 1, 2026.
First start video: https://youtu.be/ySVXcBWvT2k?si=EADb-LdS7bd9VtrJ

Sump was inspected, repaired and epoxy sealed by Okanagan Aero Engine in Kelowna, BC.
Crankshaft, camshaft, gears, and all steel parts inspected and reworked by Aircraft Specialties in Tulsa, OK.
Case halves and accessory case inspected and reworked by Divco in Tulsa, OK.
Overhauled carb from Aircraft Accessories of Oklahoma in Tulsa, OK.
New Superior Millennium cylinders.
B&C starter and B&C alternator STC's.
Real Gasket pushrod tube STC.
New Powerup magnetos.
Re-conditioned prop at Stallings Aircraft Propellor in Colt, AR.
New baffle kit from Airforms.
Since engine controls were disconnected, I allowed some scope creep and replaced my plexiglass panel above the piano keys.

Here are some pictures showing the project from start to finish.
This may take a few posts to get all of them uploaded.

Thanks to all the help from the members here!
Doug

Engine back home in the garage.

a.jpg

Cylinders removed.

b.jpg

c.jpg

Accessory case removed.

d.jpg

Case split.

e.jpg

[dstates]

My accessory case failed inspection due to a groove in the oil pump galley. If you look close you can see the groove in the left side of the galley in this picture. Divco found me a replacement accessory case.

f.jpg

The crankshaft also failed inspection (see cracks found at flange). I found a NOS crank that I sent to Aircraft Specialties. They ended up machining ten under.

g.jpg

Painting the overhauled case.

h.jpg

Installing the connecting rods

i.jpg

j.jpg

[dstates]

Case halves ready to put back together.

k.jpg

Case halves together and on the stand.

l.jpg

Gears lined up and ready to safety wire.

m.jpg

First cylinder installed.

n.jpg

All cylinders and pushrod tubes installed.

p.jpg

[dstates]

Getting closer. New starter and baffles in place.

q.jpg

New mags and alternator.

qr1.jpg

Made some transport supports ready to remove from the stand.

qr2.jpg

New engine on the airframe!

r.jpg

New plexiglass for engine controls. Painted panel black and left the plexi clear.

rs.jpg

[dstates]

Final installation, pilot side.

s.jpg

Final installation, co-pilot side.

t.jpg

Reconditioned and painted prop.

u.jpg

Ready for engine start.

v.jpg

First start video: https://youtu.be/ySVXcBWvT2k?si=EADb-LdS7bd9VtrJ

First takeoff.

w.jpg

[johneeb]

Thanks posting Doug, looks like a very satisfying result.
Johneb

[DaveF]

Good work!

Cool magnaflux picture.

[Ryan Smith]

I mostly looked at pictures my first run through this post.

I missed the part where the engine came out of N2693D at first. The project was sold…to none other than Dillon Barron and his wife. I expect to see a really nice result before long.

[GAHorn]

LOVELY POST!

(and the pics are Wonderful!)
I am curious: Why was an NOS crank necessary to be ground .010” under? Was it improperly stored, etc?

[dstates]

LOVELY POST!

(and the pics are Wonderful!)
I am curious: Why was an NOS crank necessary to be ground .010” under? Was it improperly stored, etc?

That is a great question, George. I wondered the same thing, but I don't think I ever asked the machine shop. I guess at that point it was already done.

[GAHorn]

LOVELY POST!

(and the pics are Wonderful!)
I am curious: Why was an NOS crank necessary to be ground .010” under? Was it improperly stored, etc?

That is a great question, George. I wondered the same thing, but I don't think I ever asked the machine shop. I guess at that point it was already done.

Another possibility comes to mind: I’ve been told by one of our own, who overhauls these engines, that main bearings have become scarce. This prompts me to wonder if it was ground .010U to utilize available bearings…
(what a pitiful reason, however)

[dstates]

No, it is the 0.010 under bearing that are almost impossible to get right now. The standard bearings were readily available when I was looking for some.