Help requested - rebuild of G-AFZL

[Steve Sharpe]

Hi everybody.

The rebuild is going OK, fuselage finished, wings repaired and awaiting re-cover. We have a big problem with the engine though. It looks like the old A50 is worn out, cracked crankcase which can be welded, but the cylinders are probably beyond repair.

So I'm looking for a serviceable A or C65, or 4 serviceable C65 cylinders. If anybody knows of one available for sale in usable condition I would be very interested.

Also as we will have to re-make the exhaust system can somebody please post some pictures of a typical C65 exhaust/hot air muff installation so we can see what's involved.

Thanks

Steve Sharpe

Southampton UK

6 Feb 2014

[Steve Sharpe]

Thanks for that John. We've sourced a zero SMOH A65 here in the UK, which is now mounted on the airframe, has been carefully inhibited and came with brand new mags. Someone loaned me a couple of exhaust systems to try out, one of which was OK, but we've decided to have the old one adapted - it was originally made for us by British Airways out of stainless steel, would be a pity to chuck it away! We've got a tame welder who says he can do it. You're right, a Champ system looked ideal and will be my first choice if the existing one proves too difficult for our welder.

Wings are being re-covered with Polyfiber at the moment, I will spray them, hopefully late April. Hopefully we can re-assemble early May and maybe test fly early June, subject to the usual paperwork.

The old engine could've been repaired, but the expense and time scale made it a less attractive option. Would've had new Millenium A65 cylinders as A50 upstack ones just aren't out there it seems, so wouldn't have been authentic anyway. We will keep the airframe as a CP50 though as it makes the paperwork simpler, hopefully get 5 or 10 kts better cruise speed.

ZL is now again the only Porterfield in the UK, the other one has emigrated to France.

I got lots of assistance from the Aeronca Club over here, which is run by a chap in Cornwall, we were offered 5 different engines in various states of repair, we went for the  one which needed no work. I had leads on engines in the USA, Scotland and Ireland, eventually found the engine about 3 hours drive away.

I'll post some pictures when we've got her re-assembled.

Thanks for your interest.

Regards

Steve