DIY rebuild

by Jim Cates in General Tech Discussion 6 years ago

I realize Rotax will not sell certain overhaul specific parts (specially the crankshaft, etc) to the general public, but there are many used cases, cranks, cams, heads, on the various aviation "for sale" websites. I have a great deal of experience with auto, aircraft and boat engines, I would feel confident assembling my own 912 from parts, which I would first send to a Rotax approved vendor for inspection and any necessary machine work. Given the engine will be installed in a E-LSA which I am building, I dont see an issue with this path. Has anyone done this and what are the possible caveats ?

Re: DIY rebuild

by Rob Seaton » 6 years ago

Rob Seaton

3 1.32k 240

One caveat for sure: "ignorance is bliss"
If you are not trained, very experienced, have the proper tools and equipment you are taking an unnecessary risk.
Not that they are a complicated engine, it just has some critical differences from other engines.

Thank you said by: Jim Cates

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Re: DIY rebuild

by Roger Lee » 6 years ago

Roger Lee

126 5.14k 4.61k

Agreed

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-349-7056 Cell

Thank you said by: Jim Cates

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Re: DIY rebuild

by Jim Cates » 6 years ago

Jim Cates

3 6 0

Agreed as well......the engines are complicated and far different than Lycoming and Continental, which are benchmarks of simplicity that I have worked on and flown behind for 36 years. The one piece crank/conn rod assembly confounds me as well. No other engine manufacturer has chosen this methodology that I am aware. Thanks for allowing me to see the light. The trade-off of high rpm, reduction drive, water cooling to save a few pounds over a conti or lycoming seems a rather high price to pay.

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Re: DIY rebuild

by Rob Seaton » 6 years ago

Rob Seaton

3 1.32k 240

Nice setup Jim, I fell right into that one.
Far different, yes.
I would also never recommend that a Rotax overhaul tech to dive into a Lyc or Conti overhaul: he would be so bewildered by the huge tolerances, silk string, and the 100+ extra pounds.

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Re: DIY rebuild

by Jim agua » 6 years ago

Jim agua

1 4 0

I don't believe that Rotax supports overhaul. It can be done but the cost of tooling and parts specified by Rotax is prohibitive. I just paid $4300 for the pushrod / rocker replacement (still waiting to be reimbursed) that's right - 20% of the cost of the engine is the pushrods and rockers. I do know folks that have done it and feel safe about it. There's also a place in Europe that can split the crank and put it back together.

If I were serious about overhaul I would consider one of the aftermarket performance shops and pump it up.

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DIY rebuild

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