How It's Done - Aircraft Overhaul Engine

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Precision Aircraft Engine Overhaul
Demanding Maximum Performance & Longevity

1 (650) 354-1399

2415 Embarcadero Way Palo Alto, Ca 94303

FAA Repair Station #BJ3R399L

"Power-By-Victor" Engines add higher value and hold higher
value over time. See Aircraft Resale Value Comparison.

How It’s Done

Victor Aviation specializes in overhauling and upgrading a customer’s engine and keeping the original engine serial number intact. There is a distinct advantage in keeping your engine’s serial number as this allows you to know the engine’s actual hour history and fatigue cycles on the major engine parts.

Interestingly, should you purchase a factory rebuilt “zero-time” engine, the engine may have high time major engine parts including the crankcase, crankshaft, gears, connecting rods and housings. These parts may have more engine hours and fatigue cycles on them than are on your own engine.

When the factory takes in an engine core for exchange, the engine is disassembled, the logs are discarded and re-usable engine parts go back into their rebuilt “zero-time” engine parts inventory. Engine parts are no longer kept with the original engine serial number where they came from and the parts hour history and fatigue cycles are forever lost.

You are now buying an exchange engine with an unknown parts hour history.

Exchange “Power-by-Victor” engines are available at Victor Aviation for most popular six cylinder engine models and come with engine hour parts histories. Unlike the engine manufacturers, when Victor Aviation takes in an exchange engine core, the engine components are serial number recorded and kept intact with the engines serial number.

Engines are built one-by-one by the nation’s most experienced master engine machinists that have passed Victor Aviation’s rigid training and experience requirements. With over forty two years of experience, Victor Aviation has set the standards that other manufacturers and field over haulers attempt to follow.

"Power-By-Victor" The Overhaul Procedure

Step 1

Initiating an Engine Overhaul

To initiate an engine overhaul all it takes is a phone call. Our service advisor will review the “Power-by-Victor” engine overhaul or upgrade series with you and make recommendations on what series of overhaul and options would best suit your aircraft application needs.

Step 2

The Purchase Order

After a customer has decided on what engine overhaul series and options desires, a work order contract is prepared detailing the work to be performed, terms and conditions and forward to you for your approval. An engine history form is also included to aid Victor’s technicians in understanding any existing engine operating problems.

Step 3

Engine Removal and Shipping

Upon receipt of the customers signed work order by mail or fax, a specially designed engine shipping container is prepared for your engine. These specially designed shipping containers can be transported by domestic truck lines or international air freight. The engine container is then shipped to the customer’s engine change facility complete with return shipping bill of lading instructions included.

Step 4

Engine Arrival

When the engine is received at Victor 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

Engine Teardown and Cleaning

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 Victor’s 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

Engine Inspection

Engines are inspected in accordance with the original manufactures recommendation by Victor Aviation’s National Aerospace Standards (NAS-410) certificated inspectors. Inspection processes include but are not limited to:

10X-40X Power Magnification Visual Examination
Parts Corrosion Examination
Magnaflux Inspection- Both Circular and LongitudinalAxes
Liquid Dye Penetrant Examination
Rotational Mass Parts Balance Testing
Reciprocating Mass Parts Balance Testing
Eddy Current Inspection

Cylinder Induction Air Flow Testing
Crankcase Cylinder Deck Height Inspection
Connecting Rod Alignment Inspection
Full Dimensional Parts Inspection
Research Airworthiness Directives and Service Bulletins

Following the engine inspection phase the customer will be contacted by phone to review the inspection results of their engine.

Step 7

Engine Machining

“Power-by-Victor” technicians begin the detailed machining processes required to bring the engine parts up to Victor’s close tolerance specifications depending on the customers work order requirements. Victor Aviation has a state-of the art full machine shop capable of performing the most advanced machining processes.

Step 8

Parts Preparation

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

Five Phase Engine Assembly

Engine assembly is performed by one of Victor’s top engine machinists under the supervision of the chief engine inspector. Unique to “Power-By-Victor” engines, five phases of engine assembly are inspected and signed off by the chief engine inspector.

Phase 1	Engine Parts Preparation
Phase 2	Crankshaft, Connecting Rod and Cam Assembly
Phase 3	Sub-Assembly
Phase 4	Pre-Case Closure
Phase 5	Final Assembly

Step 10

Engine Testing and Shipment

The engine and test propeller is installed into a hydraulically actuated thrust load cell to test for engine propeller 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.

An Aviator Series™ Engine Overhaul is a Proprietary Trademarked Overhaul Process created by Victor Aviation Service Inc.