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Thread: Lycoming Service Instruction O-320 150hp to 160hp conversion

  1. #1
    jrussl's Avatar
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    Lycoming Service Instruction O-320 150hp to 160hp conversion

    Does anyone have a copy (and be willing to share it) of the Lycoming Service Instruction for converting a O-320 from 150hp A2B to 160hp B2B?

    I am rebuilding my engine and, even though I already had the high compression pistons prior to rebuild (installed with no paperwork), I am now installing factory new 160hp pistons and cylinders. I need the service instruction to get all my paperwork in order.

    Thanks in advance

    Jeff
    Last edited by jrussl; 01-28-2021 at 01:02 PM. Reason: added engine designations

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    SuperCub MD's Avatar
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    SI 1304J for the engine, you can probably find it on line or I can probably dig it up and scan. Svenns Aviation for the install stc, support the locals. I wrote a cub clues article a long time ago about 320 conversions, not sure if that is available anywhere, not sure if I still have a copy, but it would be good info.
    Last edited by SuperCub MD; 01-28-2021 at 02:00 PM. Reason: Correct the efing spell ✔️
    Thanks jrussl, botto thanked for this post

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    PerryB's Avatar
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    Interestingly enough, I just talked to an employee of LyCon about this conversion. I was considering buying a used O320-A2B for a core to send them in order to build me an 8.5 engine. He told me in order to be certified it had to start life as a wide deck. He then offered to sell me a core.

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    Lycoming Service Instruction O-320 150hp to 160hp conversion

    I used Lycon’s O-320 wide deck 150 to 160 hp conversion STC. Sent Lycon my narrow deck-27 case, upgraded to the -39 case. They did the 505B inspection on the crank and ported the cylinders for me... LyCon also sent me a new data plate to be placed behind the original Lycoming data plate.


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    Last edited by Mark_Moyle; 01-29-2021 at 12:26 AM.

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    skywagon8a's Avatar
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    This subject has been brought up before: https://www.supercub.org/forum/showt...-it-10-1/page2
    Look at Darrel Starr's post #47.
    Lycoming built 160 hp 0-320s with a narrow deck. Lycon likely has their own STC which spells out wide deck only. IMO based upon a letter I've seen from a well known NY engine rebuilder, the alteration is a minor. Meaning, just comply with the parts which are described in the parts manual.

    You will need an STC to use the engine in your Cub. This is an airframe installation STC, not an STC to alter the engine.
    N1PA
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    hotrod180's Avatar
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    Seems like I've seen narrow deck 320's converted to 160hp,
    as I recall they need the banana plates installed.
    Cessna Skywagon-- accept no substitute!

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    I just happen to have a case I’m getting ready to paint and both A2B and B2B narrow deck studs here. Click image for larger version. 

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    RaisedByWolves's Avatar
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    Quote Originally Posted by PA-22/20-160 View Post
    I just happen to have a case I’m getting ready to paint and both A2B and B2B narrow deck studs here. Click image for larger version. 

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    What are you using for paint/primer? Mask off where the cyl and other accessory’s go?


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    There is a service instruction to modify B-series case’s to the 69679 stud and you can see the difference in this picture. You’ll also need hold down plates and internal nut’s to go along with the 05K21101 cylinder kits.
    You need (16) 38-13 studs, ( 50-15 studs (4) 75154 (2) 69679 Click image for larger version. 

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    I use PPG EXP-950 epoxy primer and PPG AUE-100 top coat. mask off all cylinder and accessory holes and install hardware with a washer in all holes. can post a picture when I’m done.
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  12. #12

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    Lycoming Service Instruction O-320 150hp to 160hp conversion


    Was an O-320 A2A... Lycon STC conversion to O-320 B2B using their wide deck STC...Lycon sent me the deviation document for the narrow deck conversion.

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    jrussl's Avatar
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    Thanks everyone for all the great info.

    I ordered the Svenns Aviation STC for the 160hp as my current STC only covers the 150hp.

    Boz, I went though my incomplete collection of Cub Clues and did not find the article. If you think you have it, I would sure appreciate a copy.

    And thanks for the link to the service instruction. My engine is a wide deck. Question.....other than the parts manual, is there anything other instruction for converting the A2B to a B2B?

    I will work with my A&P to deal with the actual engine conversion as minor alteration.

    This all is just to get my paperwork straightened out as my engine has already spent the last 20 years as 160hp.

    And now that the engine will be "officially" a B2B, I need to get the Peterson auto gas STC as the EAA STC will no longer apply. Sigh!

    Thanks again, everyone.

    Jeff
    Last edited by jrussl; 01-29-2021 at 12:08 PM. Reason: typo

  14. #14
    SuperCub MD's Avatar
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    The engine type certificate E-274 which lists the differences between the a and b should also be referenced. The TC, SI, current parts and overhaul manual are all approved data for your mechanic to use. I'll dig around tonight for that old clues, to nice today to stay inside.
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    Quote Originally Posted by SuperCub MD View Post
    The engine type certificate E-274 which lists the differences between the a and b should also be referenced. The TC, SI, current parts and overhaul manual are all approved data for your mechanic to use. I'll dig around tonight for that old clues, to nice today to stay inside.
    Minor correction here, manufacturers parts catalogs and overhaul manuals are not approved data, only accepted data. Remember, the overhaul of a non supercharged, non geared engine is only a minor repair. Changing models would be a major alteration, but your approved data is the SL and the TC.


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    Click image for larger version. 

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    For what it's worth, my engine was field approved to 160 in 1998 when it was overhauled last time. A2A wide deck.
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    RaisedByWolves's Avatar
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    Attachment 53834
    Quote Originally Posted by dgapilot View Post
    Minor correction here, manufacturers parts catalogs and overhaul manuals are not approved data, only accepted data. Remember, the overhaul of a non supercharged, non geared engine is only a minor repair. Changing models would be a major alteration, but your approved data is the SL and the TC.


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    Quote Originally Posted by RaisedByWolves View Post
    Comes up as invalid attachment!


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    Click image for larger version. 

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    I guess the forum didn't like a PDF.
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    Yeah, I know what that SL says, but when you look at the manuals there is no “FAA approved”, and there is no provision in CAR 13, or 14CFR 33 for approving service documents. Likewise in the Type Certification guide, they explicitly state that only the Airworthiness Limitations section is approved data. That said, many Service Bulletins, & Service Letters are Approved Data and state that. For it to actually be Approved Data, it has to state that in the document (typically on each page that is approved). Unfortunately FAA and the predecessor CAA weren’t very consistent here. In any case, it is FAA policy that if an action is a minor repair (overhaul of an engine), it is contrary to the regulations to approve data for that operation. As a DER, I can’t approve data for minor repairs or minor alterations.


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    Steve Pierce's Avatar
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    Quote Originally Posted by PA-22/20-160 View Post
    I just happen to have a case I’m getting ready to paint and both A2B and B2B narrow deck studs here.
    Click image for larger version. 

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    What are you using to install the studs? I had a stud leak after topping it and talking to Ken at LyCon found out he pulls all the studs even though the crankcase shops don't and he puts them in with Loctite but Loctite reacts from two ferrous metals and aluminum won't create that reaction. His case guy hooked me up with the correct Loctite and primer to get the seal and with the proper working time which is an issue with the other primer. Ken said he started doing all his cases this way because he got tired of dealing with it under warranty. Teledyne Continental Motors calls it out in a service bulletin on chemicals, coatings etc. Will look at the bottles when I get to the hangar.

    Oh yea, the Six just fit in his hangar. He is gonna tear it down and build a bigger hangar.
    Steve Pierce

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    A friend has a Snap-On stud extractor set that I use when the need comes along but for the most part I just let the case shop remove and install them. They have to do some machine work to install the body fit through studs to meet lycoming’s mandatory SB on B series and 540 cases seems most early A-series cases don’t have it done. Converting a narrow deck to 160 is definitely not simple or cheap like a widedeck but it’s not impossible like a lot of people think. It’s funny that you mentioned the loctite thing I just watched a clip from them last night about using their products and the need for activators and developers on different substrates you’ll have to let me know what they are using when you look.

    Glad the Six made it to Texas the look on his face when I asked if he knew you was worth the price of membership here and proves just how small the avation world is.
    Last edited by PA-22/20-160; 01-30-2021 at 11:46 AM.
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