Question: Cylinder Repair/Overhaul vs. New Cylinders

As a rookie homebuilder I am confronted with the question of whether to have
the cylinders rebuilt on my O-320 or save my pennies and spring for new
ECI/Superior or Lycoming assemblies. On one hand new cylinders would give
the comfort that new posesses. On the other hand the number of hours I
would be paying for with new cylinders seems to be much greater than the
number of hours I would actually fly my homebuilt. I am looking for
opinions from the experienced here. If I am expecting to fly 500-600 hours
on my homebuilt (is that a fair estimate?) does the purchase of new
cylinders justify the cost? Also for those of you who have had cylinders
overhauled, what are your experiences and what can I expect from the
"typical" overhauler. The four cylinders I have are off a low compression
150hp E2D. The cylinders are of various age. One is only 400 hours old the
other three all have between 1000 and 2000 hours on them. I am wide open to
your learned opinions on this subject. Thanks in advance.



Ebby
Hatz Classic my work in progress since 2001.

Ebby: For a certified aircraft you'd probably get your money back on
resale. In your case I'd let the certified overhaul shop spec out the
cylinders to see how much wear has happened. They should steer you in
the right direction. My 1963 0200A engine had less than 700 hrs TT but
did an overhaul with new intake valves, guides and rings. Compression
was a little low in 2 cylinders and was "talked into it" by my
mechanic. Oil consumption was up to 1 qt every 4 hrs so paid around
$1,000 for the whole job. I'm not sure what new cylinders cost but if
less than $2500 total for the job maybe I would have gone that route.
My oil consumption after 30 hrs is still 1 qt every 4-5 hrs and hope it
will get better with more hrs. I hear people say 6-8 hrs per qt on new
cyclinders. You might consider just doing the high time cylinders only
if you want to save some money.

Larry

Larry,

That's exactly the kind of anecdote I need to figure out what is "best". I
have already had the lower end completely overhauled by AEA. Very satisfied
and there was no question in my mind about having the overhaul done. But
with cylinders I hear they can be rebuilt. I guess what I am wondering is
the adds for $295 for an overhaul with the caviat about costs for additional
parts. So I can expect to pay considerable more than the $295 as I would be
getting new exhaust valves. I figure new cylinders for my engine would be
$800-1200 each if the rebuild is pushing that amount then new sounds like
the way to go but if typical rebuilts run $400-600 then rebuilts would be
the way to go. I guess the best way to find out is to send a cylinder to a
shop and get an estimate. Thanks for your input. Others?


--
John "Ebby" Ebensperger
Hatz Classic s/n37
Camden, NY

"Ebby" wrote in message
...
Larry,

That's exactly the kind of anecdote I need to figure out what is "best".
I have already had the lower end completely overhauled by AEA. Very
satisfied and there was no question in my mind about having the overhaul
done. But with cylinders I hear they can be rebuilt. I guess what I am
wondering is the adds for $295 for an overhaul with the caviat about costs
for additional parts. So I can expect to pay considerable more than the
$295 as I would be getting new exhaust valves. I figure new cylinders for
my engine would be $800-1200 each if the rebuild is pushing that amount
then new sounds like the way to go but if typical rebuilts run $400-600
then rebuilts would be the way to go. I guess the best way to find out is
to send a cylinder to a shop and get an estimate. Thanks for your input.
Others?


--
John "Ebby" Ebensperger
Hatz Classic s/n37
Camden, NY

I rebuilt 4 first run cylinders for the O-320 in my RV-6. I don't remember
the exact figures, but at the end of the day, I was surprised at how little
money I saved vs trading in the old cylinders and buying brand new ones.

KB

The shops in my area have taken to throwing away old cylinders on some
engines as they don't even have a core value to the rebuild shops we
use. That probably says more about the economics of rebuild vs. buying
new than anything I've heard.

I spoke with my A&P friend and he indicated that new was not going to be
that much more money than rebuilt. Pretty sure I know which road to take at
this point unless there is a much better argument for rebuilds. I'll be
saving my nickels as it seems money ends up a wash and new is new. Thanks.