Overhaul Needed any upgrade ideas?

[Warren beckles]

Hello All,

I have a 1960 250 O-540-A1D5, the idler gear broke off so I need to crack the case. Since the engine has to come off and torn apart I am considering an overhaul. (all depends on cost to fix vs overhaul).

My question is are there any upgrades I should consider while the engine is off the plane? Are there any engine upgrades that can be done?

I don't plan on selling the plane ever!!!

[Andrew Foster]

Hi Waren,
Sorry to hear about your 0-540. We have the same enigine, an A1D5 in our 61 250.
Ours is at almost 1800 so I have been thinking about overhaul options. Here's a few things I've thought about.

You could convert to Fuel Injection. per the type cert data you can do the conversion. Cost would be about 5k. Nice to have, but the carb is pretty bomb proof.

Aviation Performance Products dual exhaust is a really nice upgrade. Great product and great support. It's by far the best modification we've done on the 250. Reduces lots of the heat on the firewall and eliminated a great deal of exhaust shroud maintence. Oh yea, it makes the plane sound kool too.

Johnstons and sons has an stc that puts counter weights on the crank by the #6 cylinder for less vibration.

I've read about roller tappets, but have no idea if that applies to our engines or not.

And then of course the multitude of overhaul shops to choose from.

How did you know the idler gear broke. Was it on the ground( Hopefully)?
Please keep us posted as I'm sure I'm not the only one looking at an upcoming overhaul.
Thanks and good luck

Andrew
61 250 7533P