Step #1, Call to Contact us
To initiate an engine overhaul all it takes is a phone call (251-809-2959). We will review the engine overhaul with you and make recommendations on what would best suit your aircraft needs.
Step #2, Place an Order
After a customer has decided on what engine overhaul he or she desires, a work order is prepared detailing the work to be performed and forwarded to you for your approval. An engine history form is also included to aid AirWorx technicians in understanding any existing engine operating problems.
Step #3, Get your engine to us
The customer will build a sturdy shipping container and will crate the engine and accessories. Airworx will provide the contact info of a shipping broker if so requested.
Step #4, We receive your engine
When the engine is received at Airworx Aviation the engine, accessories and fittings are photographed with engine and accessory serial numbers recorded. Photography of the incoming engine allows the final engine assembler to reinstall any removed engine fittings or brackets to their original clocked positions enabling the engine installer ease of engine reinstallation.
Step #5, Teardown
During the engine teardown procedure the engine inspection process actually begins. Wear pattern signatures on the worn engine bearings are examined to determine how the rotating and reciprocating engine parts are aligned. This information aids AirWorx technicians to understand any past history of mis-aligned parts.
Engine parts are then separated by their material composition and go through high temperature steam, immersion and ultrasonic cleaning. To avoid any parts contamination critical engine parts will be pneumatically cleaned using special plastic bead blasting media.
Step #6, Inspection
Engines are inspected in accordance with the original manufactures recommendation Airworx technicians and certificated inspectors. Inspection processes include but are not limited to:10X-40X Power Magnification Visual ExaminationParts Corrosion ExaminationMagnaflux Inspection- Both Circular and LongitudinalAxesLiquid Dye Penetrant ExaminationRotational Mass Parts Balance TestingReciprocating Mass Parts Balance TestingCrankcase Cylinder Deck Height InspectionConnecting Rod Alignment InspectionFull Dimensional Parts InspectionResearch Airworthiness Directives and Service Bulletins
Step #7, Machining
Airworx Aviation technicians begin the detailed machining processes required to bring the engine parts and cylinders up to the manufacturers close tolerance specifications depending on the customers work order requirements. Airworx Aviation has a state-of the art full machine shop capable of performing the most advanced machining processes.
Step #8, Parts prep.
A) Engines parts are prepared for final finishing depending upon the customer work order requirements.
B) Aluminum parts are alodine corrosion treated and painted with high temperature enamel paint.
Step #9, AssemblyEngine
Assembly is performed by Airworx’s top engine machinists under the supervision of the chief engine inspector. Airworx’s engine assembly steps are inspected and signed off by the chief engine inspector.
Engine Parts Preparation
Crankshaft, Connecting Rod and Cam Assembly
Step #10, Testing
Test and ShipThe engine is installed into a hydraulically actuated thrust load cell , or a test stand with propeller to test for engine thrust and all engine operating parameters. Upon completion of engine testing all engines are final inspected by the chief inspector to assure that all operating parameters meet the original manufacturer’s specifications and work order detail requirements. The customer is then notified that the engine is ready for shipment, wrapped and crated for final shipment to its destination.