Engine Overhaul - a Quick Overview

There are two reasons MMS Aviation overhauls reciprocating aircraft engines. One is to give the operators of airplanes used in Christian ministry a top quality engine overhaul at as reasonable a cost as possible (it's still expensive). The other reason is to give MMS' apprentice mechanics the experience of overhauling an engine. It isn't likely that any of them will perform an engine overhaul in the field, but having the experience will help them maintain the engines under their care.

Heartland Embrace, a ministry in Central Wisconsin, sent their Cessna Cardinal to MMS for an engine overhaul and some airframe work. The first step was to remove the engine from the plane after which the engine was disassembled in the engine shop.

Scott starts the process by removing the propeller.



Lots of photos are taken for reference at this stage.

A digital camera is a very important tool during engine removal and disassembly, as pictures are a great help in remembering how hoses, fittings, and wiring go back in the right place. Engine accessories and many parts that will be re-used are sent to specialty shops where non-destructive inspection, reconditioning, and certification take place. MMS does not do a volume of engine work to justify having these specialty services in-house. When all the parts to be re-used are back and new parts have arrived, measuring and reassembly begins. All dimensions are kept in the engine's work records.

Geoff measures a hole in the crankcase where a tappet body will ride.

Checking the camshaft timing on the partially assembled engine.

Once the engine is back together with its reconditioned and new parts, it must be tested. Part of MMS' engine overhaul facility is a test cell, a room designed to minimize noise and provide a place for safe engine operation.

In the test cell, instrumentation is connected to monitor engine condition throughout the test.

Nearly ready to run, the test propeller is on. An air scoop will be installed to direct the cooling air over the engine.

The "hood" is up so adjustments can be made.

The Heartland Embrace engine was operated briefly in the test cell yesterday afternoon. The full test will be performed Monday. Stay tuned.

Just Plane Busy

Today, MMS Aviation mechanics work on airplanes of five different missionary/ministry organizations.  It's a balmy 61° in Coshocton, a brief break from more typical January temperatures.  Last Friday we were reminded again that it is winter in central Ohio.

In the hangars we're quite comfortable, so here is a quick tour of the aircraft maintenance being performed.

After its test run following overhaul, the engine for the LAMP Piper Lance was placed back on the plane by Josh and Andy.  Terry finished the installation, attaching hoses, wiring, engine controls, etc.

An annual inspection of this Cirrus SR22 nears completion.  A large church in the Chicago area uses this plane in support of its ministry.  Jake and Ben have assisted Mike with this project.

Dale shows Andy the plan for modifying this Cessna 206 horizontal stabilizer.  Today, they removed the aluminum skins and began repair of the internal structure.

Earlier this week, Dale and Andy took the "tail feathers" off of the MAG Cessna 206.  Behind Andy, through the door in hangar B, is the MAF 206 that is being re-assembled after its restoration.

Wings were put back on the MAF 206 a week ago.  Chuck and Phil continue the assembly and rigging of all the flight controls as well as fitting a new cargo pod on the fuselage.

Geoff measures the crankcase of a Lycoming engine for a Cessna Cardinal used by a ministry in Wisconsin.  Geoff works under the supervision of Josh on this engine overhaul.

A New Year

January 2nd came right on schedule and the MMS Aviation team returned after the holiday break.  Each year the first order of business is to do physical inventory which is a rather mundane task but necessary.  Doing inventory is a lot like eating the vegetable you don't like first so you can enjoy the rest of the meal.

Tables placed near the standard hardware shelves make inventory easier.

Inventory typically takes a day and a half and is followed by review of the MMS Standard Operating Procedures Manual.  Then, and only then, we get back to the fun stuff.

 



Andy installs the lifting brackets on the Lycoming engine being overhauled.

Many annual inspections of aircraft are scheduled during the winter months and MMS has several lined up.  Some of these are for ministry organizations and other planes we'll inspect are owned by local people.  Regardless, the experience gained by MMS apprentice mechanics doing routine inspections and the maintenance that comes with them is very valuable.

 

 

A locally owned Cessna 310 was first on the list of annual inspections this year.

Restoration of a Cessna 206 for MAF enters an exciting phase this month.  Repair is complete and assembly of the airframe components is underway.  This airplane has been assigned to MAF's recruiter in our area and last week John dropped by to see how work on the 206 is progressing.

 

John, on the right, talks with MMS staff, Josh Adelsberger, about the plane.

 

MMS on 12-12-12

Just thought I'd post a few pictures of what's happening in the hangar this 12th day of the 12th month in the 2012th year of our Lord.

 Andy safety-wires a component of the engine for LAMP's Lance.

 Chuck and Geoff apply masking to the rudder of the MAF 206 in preparation for shooting the color coats (red & blue) on the fuselage.

 Terry McClary works under instrument panel of the LAMP Lance.

 Ben and Bob install the baffling on the 172's new engine.

Safely up from Rus Rus, Honduras this MAG 206 waits for restoration to begin in preparation for its deployment to Guatemala.

Amazon Salt & Light's Cessna 185 awaits paperwork completion and its return to service flight.

N9719Z Has Arrived In Rus Rus

We're pleased to confirm that MAG's Cessna 206 has arrived safely in Rus Rus, Honduras.

N9719Z is in the background on the flight line in Rus Rus.

The white and red Cessna 206 in the foreground will soon be flown up to us to be inspected, repaired, restored, and prepared for ministry in MAG's new flight program in Guatemala.

MAG's Cessna 206 Departs for Service in Honduras

After being modified for operations in remote and rugged locations, Missionary Air Group's (MAG) newly acquired Cessna 206 departed MMS in preparation for its deployment in support of MAG's jungle hospital in Rus Rus, Honduras.

 

The arrival of this airplane in Rus Rus will allow the Cessna 206 currently operating in Rus Rus to be flown to our facility for restoration. After this next 206 is inspected, restored, and repaired it will be deployed to Guatemala where MAG is preparing to open a new field of operations.

Initial Engine Run of Mission Beyond's Zenith 801