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Finally flying again in the Legacy. After installing the starter adapter with an undersized "M015" spring and testing with the old style TCM 24v starter, the mags were reinstalled, timed and tested.
While everything was off the engine, we had all the p-leads tested to ensure they grounded the mags when the switch in the off position. All of the plug wires and connections were cleaned because we had time to do it. These tests are all about making sure that something doesn't start spinning when you least expect it.
With everything installed we tested each mag and each plug to ensure they sparked at the correct cylinder and in the proper order. Just to be sure. Then we spun everything up a few times without fuel and then ran the engine for a leak check. A few flights later and I can say that the minor oil leak I had is gone and was probably from the bad threads on the starter adapter studs in the crankcase. I wrote about that thread damage in another note and decided to call TCM. They suggested cleaning the threads versus replacing the studs. That worked really well and avoided pulling studs and having to install a helicoil in the crankcase.
The TCM starter is wickedly powerful and spins the IO550 at about 50%-100% faster than the ISKRA did on its last days. I am very pleased going back to the old style starter and having my original starter adapter fixed with the new spring and shaft dimensions.
The job does require an engine hoist but that it actually easy on the Legacy since only the engine mount bolts and one fuel line had to come off. Lifting about 2-3 inches provided enough clearance to pull the starter adapter off. To get flying again I had to use:
1) The Mag Shop in Daytona ($600)
2) Craigslist for the engine hoist ($100)
3) Aircraft Specialties in Tulsa for the starter adapter repairs ($50, $75, $250) and technical assistance.
4) Two local FBOs for labor and assistance
5) Aircraft Spruce for bearings & hardware 6) Niagara who provided extensive assistance and who will hopefully refund the failed starter adapter and shipping costs as offered.
Aircraft Specialties has provided a bulletin on Starter Adapter repairs including technical drawings and troubleshooting. It am attaching it here for future reference.
Paul
Spruce Creek
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