When I purchased my Lancair 360, it had 15hrs TTAF and SMOH and a know issue with excessive oil consumption.  We attributed this to the chrome cylinders never properly seating (not a rare problem).  When it did not improve after about 50hrs, my mechanic suggested trying new rings and glaze breaking the cylinders (I was still in the post-purchase checkbook phase). 

 

Not surprisingly, this did not accomplish much and the engine (with 150hrs SMOH) went in for new cylinders at one of the oldest and most established engine shops in the North East . However, the shop discovered a spun bearing and so I opted for the 1st class overhaul with dynamic balancing, etc.  I spoke to the small Florida shop that did the original overhaul and they would not cover any of their work since it had been several years.

 

Last week, at 370hrs SMOH (the second one) I discovered material amounts of aluminum material in the filter.  I discovered that I had excessive piston pin plug wear.  It turns out Lycoming issued Service Instruction 1492C, which addressed problems with excessive piston pin plug wear.  Lycoming addressed this by extending the warranty for Lycoming new or Lycoming factory rebuilt engines from 1year to 3.

 

I spoke to my Engine shop manager and they said "it is just one of those things" and they don't have a good answer.  I spoke to Lycoming and the technician could not offer any advice other than replace the parts and try again.

 

Obviously I am not thrilled pulling my cylinders off at 370hrs , previously believing these early top end problems were the domain of the IV(P) people running boosted engines at high altitudes/power/temps. 

 

My questions and comments are:

-what exactly happened (bad part? bad install?, maintenance? operation)?

-as the owner/operator, what can I do to help prevent this?  I believe I have always followed a conservative maintenance and operating policy.

-I am disappointed (but not surprised at the support).  Lycoming acknowledges that there is a problem, but extending the warranty to 3 years and only to New and Lycoming factory rebuilt engines is not much support for an engine with a typical design TBOH of say 15 years (non commercial applications) or to those that had someone other than Lycoming (ie, most people) perform the overhaul.

 

Regards,

Clark Baker