Aircraft maintenance often presents unexpected challenges, and staying ahead of potential issues is key to safe flying. When Glen from Glen’s Hangar set out for another routine adventure, he encountered persistent engine stumbles mid-flight.

Glen traced the problem to an outdated Case Magneto, a relic of aviation history that was no longer serviceable. Instead of searching for costly rebuild options, he decided it was time for a significant upgrade.

Glen and his mechanic, Chris, tackled this essential ignition system upgrade using a Hartzell PowerUP Magneto.

“Here’s the old one—this is a Case Magneto. This was probably designed in the 30s… before that. Made by a tractor company, and this is what originally came with the aircraft. But they can’t be rebuilt—there’s nobody in our area that will rebuild them. I just got laughed at. It’s a boat anchor.” – Glen.

Why Upgrade Aircraft Magnetos?

A magneto is a crucial part of an aircraft’s ignition system, generating the spark for engine combustion. Glen needed to upgrade his magneto because his aircraft, C-FMVU, had experienced engine stumbles during recent flights due to the old Case Magneto.

Glen opted for a new PowerUP Magneto with no local rebuild options, which offers modernized components and enhanced durability. PowerUP Magnetos improved upon older designs by upgrading internal parts that previously had airworthiness directives (ADs) or service bulletins, ensuring better performance and reliability.

By upgrading to a PowerUP Magneto by Hartzell, Glen improved engine reliability, start-up performance, and overall smoothness while eliminating the risk of future failures from an aging ignition system.

The Upgrade Process

With the help of his mechanic, Chris, Glen walks through the step-by-step installation, which includes:

• Removing the old Case Magneto, originally designed nearly a century ago.
• Installing the new PowerUP Magneto ensures a proper fit and alignment.
• Transferring and securing the gear drive from the old magneto to the new one.
• Fine-tuning the timing by carefully adjusting the magneto body to ensure the ignition system fires at the correct moment.

Chris shares expert insights on magneto timing, explaining how even minor adjustments can make a noticeable difference in engine performance, from smoother starts to potential improvements in cruise speed.

“[You’re] not really going to get any more power out of that engine, but it’s going to be more reliable. Better starting, better everything.” – Glen

Viewer Comments

“I really enjoyed this video, Glen! You’ve got a great mechanic there. As an AME myself, (retired!) I would like to make his acquaintance someday. MVU is getting better all the time! Thank you for sharing this video!”

“Very informative, along with some nice views. Great video! Thanks, Glen!” 

“Glad you have a new magneto. What a friend you have in Chris.”

Final Results & Test Flight

After completing the installation and run-up tests, Glen takes C-FMVU for a test flight to ensure everything functions correctly. While the engine starts smoothly and runs well, he notices that the idle speed has dropped too low to 250 RPM. At Chris’s shop, they adjust it to bring it back up to a stable 650 RPM.

With the idle speed corrected, Glen carefully monitors all engine indicators during the flight. The upgraded magneto delivers the expected improvement—smoother starts, more stable engine performance, and better overall reliability.

Watch The Video

Watch the full video to see the installation process in action. Be sure to subscribe to Glen’s Hangar for more aviation upgrades and insights. Check back toHartzell Aviationfor more resources on aircraft and aviation maintenance.

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