AEROVEE TURBOCHARGER REBUILD
Seized Turbo2/20/2019: I bought the turbo kit used from another builder. It came partially seized and took a lot of effort to move it. After researching the turbo I found replacement parts and decided to rebuild it.
Dirty and Rusty2/20/2019: The turbo while asthetically not great - just needed a good cleaning and a replacement cartridge.
Leaking Oil2/20/2019: The turbo was leaking oil from the passages and the bearings. It made for a fun cleanup.
100LL Left Its Mark2/21/2019: The 100LL used by the previous owner left blue crud all over this turbo. Luckily brake cleaner works pretty good at removing it.
Corrosion and Rust2/21/2019: Youc an see the previous corossion and rust, not worth even saving this cartridge - throw it out!
Hot Side Revealed2/26/2019: Removed the hot side afer soaking everything in oil and she finally came apart.
Cold Side Revealed2/26/2019: After finally getting the right ring pliers (DO NOT USE HARBOR FREIGHT) I was able to get the cold side off. Lots of 100LL residue everywhere!
Cold Side Clean2/26/2019: After using a brass brush and lots of brake cleaner, I was able to get her nice and clean.
Taped the Exhaust2/27/19: Taped the exhaust and prepped the hot side of the turbo for a ceramic coating. This should keep the cowling cool and help transfer heat out the exhaust pipe.
Sprayed and Drying2/27/2019: I sprayed the hot side and placed it in front of my kerosene heater for a few hours to give it the initial drying.
Bake It2/28/2019: To finish off February I baked the turbo three separate times to ensure a fully cured coating. First at 200deg for 30 min then 375 for 30 min and finally at 500 for 30 min. Each time letting 45 minutes in between to cool. We will see how it hodls up.
Reassembled3/1/2019: After letting 24 hours to cool I reassembled it and it has never looked so good. Very happy with the results.
Like the engine, I purchased the turbo kit used from another builder who gained a lot of time behind the turbo before deciding to upgrade to a different engine. He told me from the onset he was concerned the turbo was seized and it was upon arrival to me. It took a lot of effort to spin the shaft so I decided to just rebuild the turbo. The turbo that Sonex uses is cartridge based and as such the replacement wheel, shaft, and bearings are sold as one assembly. This makes disassembly and replacing the guts of the turbo exceptionally easy and ridicuously cheap. The only thing is to get a really good snap ring plier because the cheap ones from Harbor Freight are not strong enough and will fail just as you think the ring will come off (ask me how I know). After diassembly, I cleaned everything with a brass brush and brake cleaner, prepped, and painted the hot side of the turbo with a ceramic coating meant for this application. I am hoping that the coating holds up and I am very impressed at the final product and results of the rebuild.