Approved Repair Alteration Processes

Welding of Merlin Engine Castings
Approved Process for Weld Repairing of Merlin Engine Aluminum Castings.

Valve Seat and Guide Replacement
Approved Process for Replacing Valve Seats and Valve Guides using Roush Valve Guides and Seats.

High Volume Oil Pump
Approved Alteration to increase volume output of Merlin and V-1650 Oil Pressure Pumps.

Lower Crankcase “Oil Pan” – Carbon Fibre Reinforcement
Approved Alteration to reinforce the lower crankcase “old pan” to strengthen weak areas prone to cracking.

Lower Crankcase “Oil Pan” Weld Repair
Approved Repair to Weld Repair cracked areas on lower crankcase “oil pan”.

Replating of Plain Bearings
Approved Process to replate V-1650 and Merlin engine plain bearings using original Rolls Royce, Packard, and Military data.

Replating of Fasteners and other Steel Parts
Approved process to replate original fasteners and hardware.

Repair of Main Bearing Bores
Approved process to repair Main Bearing Bores by Align Boring and/or replacement of Main Bearing Caps with new Roush Main Bearing Caps.

Connecting Rod Reconditioning
Approved Processes to recondition original Packard and Rolls Royce Connecting Rods, including Shot Peening.

Special Oversize Base Collars and Machining of Base Collar Bores
Approved process for repairing cylinder banks by machining triple seal bores and installing special Roush oversize base collars.

Camshaft Lobe Oil Holes
Approved Process to machine additional oil holes on the camshaft lobes to provide lubrication to the camshaft and finger follower interface.

Bearing Can Sleeve Repair
Approved process to repair worn and oversize bearing can bore in reduction gear cases.

Propeller Shaft Repair
Approved process to repair worn propeller shaft diameters.

Propeller Nut Repair
Approved process to repair seal diameter on propeller shaft nut.

Copper Beryllium Valve Guides
Approved process to install Roush copper beryllium valve guides in Merlin and V-1650 cylinder heads.

Cylinder Bank Lower Seal Bore Repair
Approved process to repair triple seal bores in cylinder banks.

Cam Tower Pad Repair
Approved process to repair worn and fretted cam tower pad areas on cylinder heads.

Generator Driveshaft Repair
Approved process to repair worn seal areas on generator drive shafts.

Header Tank O/S Threads and O-ring Cap
Approved process to repair worn and corroded Header Tank Filler Cap Threads by machining Header Tank for Oversize Filler or Pressure Cap. Additional machining can be done to Header Tank to incorporate o-ring type seal instead of copper crush gasket.

Oil Line Repair
Approved process in repair oil lines by replacing damaged tubing with new thicker wall tubing. All oil lines fabricated in accordance with original Packard Drawings and Materials.

Mixture Shaft Repair
Approved process to repair worn diameters of mixture control shafts.

Mixture Shaft Support Bracket Repair
Approved process to repair worn mixture shaft support bracket bores.

Nikasil Liner Bore Plating
Approved process to repair cylinder liner bores by plating with Nikasil. This is the better then chrome liner plating or the original steel liner bore. Will not corrode, retains oil film, and is easily repaired in the field.

-7 Rear Supercharger Cover on -9 Engine
Approved process to install a V-1650-7 rear supercharger cover and carburetor inlet elbow on a V-1650-9 engine. This will allow the use of a matched PD18-C1A carburetor and discharge nozzle on a V-1650-9 engine. For proper fuel flow the carburetor must by operated with it’s matched discharge nozzle.

Rocker Shaft Repair
Approved process to repair worn diameters of rocker arm shafts.

Silicone RTV
Approved process to replace selected gaskets with specific silicone RTV sealant.

Intermediate Driveshaft Alteration
Approved process to alter intermediate drive shafts for improved bearing support, decreased bearing wear. Reduces bearing wear by 2/3, improved bearing life!

Supercharger Oil Line Check Valve
Approved process to install a check valve in the oil line the supplies oil to the Rear Supercharger Impeller Bearing. Keeps oil in the engine, not on the hangar floor.

Upper Vertical Driveshaft Shotpeening
Approved process to remove residual tensile stresses and stress risers found in the Upper Vertical Drive Shaft.

Transport Heads and Banks
Approved Process to install Rolls Royce Transport Style Heads and Banks on V-1650 engines.

Aftercooler Pump Shaft Repair
Approved process to repair seal diameter on Aftercooler Pump Shaft.

 

For more information contact:

Paul Draper
Repair Station Manager
Email: paul.draper@roush.com
Office: (734) 779-7173
Mobile: (734) 891-4199

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Pistons

Roush Aviation’s FAA PMA pistons are machined from Aerospace Quality 2618-T61 Aluminum Forgings. Using technology and knowledge gained from experience in motorsports and performance engine development, our pistons are redesigned from the original Packard and Rolls Royce Pistons to create a piston with better operating characteristics over the original piston design. All of our pistons now come standard with anodized piston ring grooves and domes. Additionally, our pistons can be ordered with our optional thermal barrier dome coating and / or optional friction reducing skirt coating. Pistons are available for 5.395”, 5.400”, 5.403” and 5.405” bore sizes.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com>

 

Piston Rings

Roush Aviation’s FAA PMA piston rings are designed to operate as a set to work with our PMA piston. The ring set consists of a moly filled steel compression ring, a moly filled steel oil scraper ring, and a two piece iron oil supply ring. This modern ring package provides optimum compression sealing and oil control, with a reduction in drag from the original ring package.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Piston Pins

Roush Aviation’s FAA PMA piston pins are manufactured from aerospace quality AMS 6260 steel alloy. These pins are designed as replacements for the stronger Rolls Royce Transport Style Piston Pins. Our PMA pins are available in sizes from Standard to 0.020” oversize.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Piston Pin Bushings

Roush Aviation’s FAA PMA piston pins are manufactured from aerospace quality Aluminum Bronze alloy. Our PMA bushings are precision machined to higher quality and tolerances than the original parts. Our PMA Bushings are available in sizes from Standard to 0.020” oversizes.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Cylinder Head Nuts (V-1650 and Transport)

FAA PMA Steel Head Nuts are a direct replacement for the original bronze nuts. These nuts are made from AN fastener grade material and are substantially stronger than the original Packard or Rolls Royce parts. Available for Packard and Rolls Royce Transport styles.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Camshafts (V-1650-7, -9, Transport D26917)

FAA PMA camshafts made from aerospace grade 8620 material and available in three different profiles: V-1650-7, V-1650-9, and Rolls Royce Transport 620 (D26917). Camshafts are selectively hardened on the lobe surfaces only with a thicker cross section on the quill to alleviate the problem of cracking found with original camshafts.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Roller Camshafts and Rocker Arms

FAA PMA Roller Camshaft Package. This is ultimate upgrade for the Merlin Engine. Reduced maintenance, virtually no wear, no chrome or carbide pads to worry about. Our special roller camshafts are manufactured to the same detailed processes of our standard camshafts. However, they are specially ground to work with our FAA PMA 17-4PH stainless steel roller rocker arms.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Valve Springs Sets (V-1650-7, -9 and Transport)

FAA PMA replacement valve springs manufactured to the highest quality spring wire and tested to over 10 million cycles without failure. Available in sets to work with V-1650-7, V-1650-9, and Rolls Royce Transport engine spring seats and retainers. Available in sets only, not available individually.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Inlet Valves

FAA PMA replacement Inlet Valves, manufactured from Inconel X751 with Stellite weld inlay on the seat and tip surfaces. Our valves are manufactured from a stronger high temp alloy material than the original valves. Our FAA PMA Valves are compatible with original valve seats and guides or our FAA Approved valve seats and guides.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Exhaust Valves

FAA PMA replacement Inlet Valves, manufactured from Inconel X751 with Stellite weld inlay on the seat surfaces and a tool steel tip. Our valves are manufactured from a stronger high temp alloy material than the original valves and are sodium filed like the original valves. Our FAA PMA Valves are compatible with original valve seats and guides or our FAA Approved valve seats and guides.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Spark Plug Insert

FAA PMA replacement Spark Plug Insert manufactured to the original drawings and specifications.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Spark Plug Insert Nut

FAA PMA replacement Spark Plug Insert manufactured to the original drawings and specifications.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Ignition Harness

FAA PMA replacement Ignition Harness and Spark Plugs. Stop using old, unknown condition, expensive spark plugs. Switch to our ignition harness and spark plugs and save money and maintenance time. Our Harness has been thoroughly tested in all conditions, up to 37,000 ft altitude, rain, IMC conditions, without failure, issue, or increase in RFI noise.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

RA-QL57 Spark Plugs for Ignition Harness

FAA PMA replacement Ignition Harness and Spark Plugs. Stop using old, unknown condition, expensive spark plugs. Switch to our ignition harness and spark plugs and save money and maintenance time. Our Harness has been thoroughly tested in all conditions, up to 37,000 ft altitude, rain, IMC conditions, without failure, issue, or increase in RFI noise

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

3/8” Exhaust Stud

FAA PMA replacement 3/8” exhaust stud hardware manufactured from stainless steel to decrease degradation due to corrosion. FAA PMA’d for V-1650-9 and Rolls Royce Transport, and available as an upgrade to V-1650-7 cylinder heads through our FAA Repair Station.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

3/8” Exhaust Stud Nut

FAA PMA replacement 3/8” exhaust stud hardware manufactured from stainless steel to decrease degradation due to corrosion. FAA PMA’d for V-1650-9 and Rolls Royce Transport, and available as an upgrade to V-1650-7 cylinder heads through our FAA Repair Station.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

3/8” Exhaust Stud Lock Washer

FAA PMA replacement 3/8” exhaust stud hardware manufactured from stainless steel to decrease degradation due to corrosion. FAA PMA’d for V-1650-9 and Rolls Royce Transport, and available as an upgrade to V-1650-7 cylinder heads through our FAA Repair Station.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Coolant Header Tank Pressure Cap

FAA PMA replacement Coolant Header Tank Pressure Cap. Our Cap contains a schrader valve in the cap to pre-pressurize the coolant system before flight or use it to pressurize a cold system to perform a maintenance leak check. Pre-pressurization of coolant system with shop air to 14-15 psi prior to operation will increase the boiling point of the coolant by 45°F (25°C). This will reduce the risk of having localized boiling in the cylinder head which leads to cylinder head cracking. Our Header Tank Pressure Cap is also available with an o-ring type seal, by sending your header tank to our FAA Repair Station for alteration. Additionally both caps are available with oversize threads to repair header tanks with damaged threads.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Coolant Header Tank Pressure Relief Valve

FAA PMA replacement Coolant Tank Pressure Relief Valve. Our FAA PMA Relief Valve is designed to accurately control coolant system pressure at 34-36 psi. This Valve does not open early and bleed off pressure before its set opening point like the original valve.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Propeller Shaft Seal

FAA PMA replacement Propeller Shaft Seal. Our FAA PMA replacement propeller shaft seal is made by the original manufacturer using newer technologies in shaft seal design.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Supercharger Impeller Shaft Sealing Rings

FAA PMA Supercharger Sealing Rings. Our FAA PMA Supercharger Impeller Shaft Sealing Rings are manufactured to the original drawings, materials, and specifications. Both front and rear rings available.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Wheelcase Stud

FAA PMA replacement Wheelcase Attaching Studs. Our FAA PMA Wheelcase Studs are made to the original drawing and specifications using stronger material. This joint of the Merlin engine sees high loads due to the transmission of power to the supercharger. Manufactured and FAA PMA’d to replace worn and fatigued original studs.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com

Rocker Arm Lash Adjusting Tool

Roush Aviation Rocker Arm Lash Adjusting Tool with built in Torque wrench. Built-in torque wrench allows proper lash adjustment and torque tightening of tappet.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com>

 

Timing Plug Socket

Socket specially made for removing timing plug from lower crankcase.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com>

Propeller Shaft Rotating Tool

Tool to rotate the crankshaft, when the propeller is off the engine.

Bill Armour, Part Sales
Office: 734-779-7365, Fax: 734-779-7997
Email: William.Armour@Roush.com>