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1-29-10: Delivered modified IO-540 to Proxy Aviation Systems in MD for use in high altitude UAV.

1-09-10: Brought Matt Hall's new lightweight exhaust down to MX.

11-4-09: Nicolas Ivanoff and Bruno Marliere visit our facility before heading west to LyCon.

10-29-09: Another visit to MX to test fitment with their new lower cowl.

5-17-09: Brad Huelsman brings Mike Goulian's RBAR plane by to get fitted for a new Lightweight 6/1 Exhaust System.

3-7-09: Sky Dynamics visits MX Aircraft's facility to test our new lightweight systems on Alex Maclean's RBAR plane

IO-540 Turbo Conversion for High Altitude UAV

We recently completed another turbo conversion on a parallel valve IO-540 meant for powering a high altitude drone. With components from Kelly Aerospace, we built the system to deliver the necessary power to climb to 25,000+ MSL where the UAV will be programmed to loiter for up to 12 hours while taking high-resolution 3D images of the landscape. A turbo conversion like this one relies on careful heat management techniques because this platform is a tightly-cowled, pusher-type aircraft. Because this engine is in an electronics-heavy UAV, the project also required us to build an independent mounting system for a second alternator.

Lightweight IO-540 Cold Air Intake System

Introducing our latest and greatest - after months of working with various grades of material and perfecting the forming process, our lightweight intake system is now available. The lightweight system is over 3 pounds lighter than our standard intake system, which was already the lightest and most powerful system on the market. Each intake tube assembly weighs just over 6 ounces (195 grams) and the weight of the complete intake system (plenum, tapered tubes, and flanges) is only 5.93 pounds (2.69kg). Because the lightweight intake tubes are a direct replacement for our stainless tubes, the lightweight tubes can be ordered by themselves to upgrade an older system. Fittingly, the first lightweight system has been anodized gold and shipped to 2009 Red Bull Air Race Champion, Paul Bonhomme.

*We are now including Titanium fasteners with our Lightweight Systems for even more weight savings*

Thrust Dyno for Tailwheel Aircraft

We are now able to accurately and safely measure thrust produced by an aircraft. Our thrust fixture is built on a steel frame and uses floating pads for the main gear and tailwheel. These pads slide on linear bearings to eliminate inconsistent friction losses during testing. The pad for the tailwheel is height adjustable so that we can raise the tail to a true level-flight position. With the aircraft positioned and securely strapped down, we measure Thrust, RPM, and Air/Fuel ratio in real time and record the data for later analysis. Pictured above is an RV6 during a recent round of rocker arm testing.

Fuel System Development

After years of perfecting our intake and exhaust system designs, we are now prototyping parts for a complete fuel system upgrade. Our system will replace the entire Lycoming system - pump, servo, lines, distribution, and injectors. While each component is designed for increased flow, the immediately apparent benefits will be in the fuel flow consistency between cylinders, proper fuel atomization in the port, and the ability to easily fine tune the fuel delivery. Also, by removing the airflow-metering unit from inside of the servo bore, the intake tract will be wide open to allow air to flow freely into the plenum. Click on the 'Fuel Systems' button for more info.

Performance Rocker Arms Are Now Available

We have been working on a new line of High-Lift, Adjustable Rocker Arms that have shown significant power increases on the dyno. The first stage Rocker Arm Upgrade increases valve lift by over 10% and is a bolt-on installation for PV Lycomings with flat tappet camshafts. The second stage is based around an extreme lift rocker arm that requires more advanced install procedures and includes upgraded rocker pins and bushings in addition to the rocker arms and pushrods. These rocker arm kits are the first in a series of products that will increase power as well as stabilize and add consistency to the top end of the engine. We are also developing solid lifters and top cylinder girdles that will eliminate any unwanted movement from the valvetrain due to the hydraulic lash adjusters and cylinder shake at high cylinder pressure. Click on the 'Engine Components' button to see more info and pricing.

Cub Crafters Super SportCub Lightweight Exhaust and Intake Systems

Cub Crafters contacted us to help create the lightest and most powerful Intake and Exhaust Systems possible for their newest Cub iteration - the Super SportCub. What we were able to come up with impressed even ourselves and compliments CC's latest design perfectly. Each Aluminum Intake tube blank weighs just over 3 ounces, the entire 4/1 Collector-Style Exhaust weighs in at 6.25 pounds. The overall lightness of the airframe (867lbs empty) gives the plane incredible vertical performance at over 2100ft/min initial climb.

Over the years, we've relied on real-world results from our thousands of satisfied customers to be sure that our products were the best available.

Now, we can fine tune our systems even further with our own Dynamometer Test Cell. Starting with a suitable hydraulic power absorption unit, we've built a rock-solid dyno assembly to safely and accurately test Lycoming 4 and 6 cylinder engines. Our dyno cell uses electronics from the best names in the data acquisition and measurement industries such as Omega Engineering, Innovate Motorsports, and UMA Instruments. Whether you're in need of 5 more hp to stay ahead of the competition or you're looking for the safest way to have a fresh engine broken in, our combination of knowledge, equipment, and workmanship will assure you of having the strongest engine package available.

Interested in losing weight? We're coming up with new ways everyday to reduce the weight of our components.

We're now building lightweight exhaust systems for the air race market. In the past, the racers had been forced to use our standard aerobatic system which is intentionally overbuilt for strength and longevity. Those two attributes, along with high power output, are the most important factors for aerobatic pilots who expect hundreds or thousands of hours of trouble-free performance from the system. Now, we are offering our high-output exhaust systems in a lightweight package. Initial prototypes are resulting in full 6/1 systems that weigh a scant 9.75-10.5 pounds, depending on application.

Leading Supplier of  Exhaust, Intake, and Oil Sump Systems to the Red Bull Air Race Planes

Parts Supplier to Major Exhaust Overhaul Facilities