IO540 replacement on 71 260C

[Eric Jones]

Well, it did not last long. I was hoping to make it a few years, but time is not on my side. Need to replace the engine. My plan is to keep this plane and spend the money to do it right. New interior. Paint. Upgraded panel. Might even be a show 260C when done. It will be in my life a minimum of 15 years. With that said, do I go with lycoming direct or a Poplar Grove rebuilt? I am leaning toward lycoming rebuilt even though it is 8K more. Thoughts?? I am in southeast wisconsin, close to poplar grove. Anyone experienced with poplar grove with the 540???

[Kristin Winter]

How many times has your engine been overhauled? Do you have any work orders or parts lists from previous overhauls that might tell us whether there were problems with the crank or case. Attached is the result of one of Aviation Consumer's recent surveys. It should be noted that Charlie Melot or runs Zephyr is an ICS member and Twin Comanche owner.

[Eric Jones]

It is original engine, rebuilt once in 1979 due to gear up landing, 1800 hours on it since overhaul. 3600 hours on plane.
Thank you for the information!

[Kristin Winter]

The engine should be good for another field overhaul or three, assuming that there is a lot of meat left on the crank. I would probably go with a field overhaul where it my aircraft. Poplar Grove seems to be a reasonable choice. I remember G&N engines that used to be around there and had an excellent reputation. i had them do a couple of Aztec engines back in the 80's, but i haven't heard much about them lately.

[Eric Jones]

I am actually leaning toward Zephyr based on being thousands less than Poplar Grove as well as having a very good reputation. Seems not really logical to use Lycoming unless the engine was 10,000 hours.....but again, I am looking for suggestions or help that others have had. The link sent above even had Zephyr rated the best, although not sure how long ago that was.........Dealing with tens of thousands of dollars, I hate the thought of doing it 'wrong'.......I do plan on keeping this plane a very long time.

[N3322G]

Eric,

Went through the same analysis awhile back and ended up writing an article for the mag - see the bottom of the Engine list
http://www.comancheflyer.com/NS/tech_articles.php

Since this was written, we did a partial panel O/H (see Panel Renovations article) and made 'massive' changes in baffling. Kristin took the baffles even further and I'd suggest her implementation over ours for a Twin, singles of course would be different.

Hope this helps.

[Kristin Winter]

Zephyr has been on top the last couple of surveys which they have done every four years or so. They probably have a pretty good rate with one of the shippers, so that portion might not add too much to the cost.

[MULEFLY]

I'm in Southern WI too... my engines went to Charlie and the gang at Zephyr. Thru a prior business investment had some pretty souring dealings with the folks at PG.
Jim