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Backcountry Pilot • Big Bore 1484 cc conversion for Rotax 912S

Big Bore 1484 cc conversion for Rotax 912S

Lycoming, Continental, Hartzell, McCauley, or any broad spectrum drive system component used on multiple type.
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Re: Big Bore 1484 cc conversion for Rotax 912S

Sent Hal a deposit for a 1484 high power kit. If weather cooperates I will fly to Elko for the install before High Sierra Fly-in. :D :D :D

Thanks to Big John and Courierguy for info on the kit.
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Re: Big Bore 1484 cc conversion for Rotax 912S

BTV wrote:Sent Hal a deposit for a 1484 high power kit. If weather cooperates I will fly to Elko for the install before High Sierra Fly-in. :D :D :D

Thanks to Big John and Courierguy for info on the kit.


Hope to see you at the flyin, perfect time for some more HP.
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Re: Big Bore 1484 cc conversion for Rotax 912S

BTV,

Go by your local CAT parts shop before heading out, and pick up some new 8 mm locking nuts for your exhaust, mine damn near came loose 4 hrs later even though we torqued properly and they had only been off once since new. The Rotax ones should be considered SINGLE USE, and the CAT shop ones are better plus cheaper then more of the Rotax ones! Hal is a big proponent of (when applicable) CAT parts over Rotax, and he knows WHY they are better. One example is the seals on the pushrod tubes, the yellow CAT ones hold up to several hundred more degrees then the stock Rotax ones. The fact they cost about three times less is the bonus. I get my oil filters from CAT now also, ask Hal why.

Wow, quite a flight you have planned, I think you'll like it, the Zipper that is, I sure like mine. The cooler temps the last few days have really highlighted the extra power I now have, I just always seem to have a lot more throttle left over then before, as good a way as any to describe it. When you realize you are a very long ways from home and your engine is taken apart.... you may have buyers remorse, I know I did for a couple hours, that will quickly pass, hang in there [-o<
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Re: Big Bore 1484 cc conversion for Rotax 912S

CG thanks for the tip. I will definitely pick some up and anything else Hal recommends.

I've been using the tempest filter. I wonder if it is any better than the Rotax. What is the Cat filter Hal recommends.
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Re: Big Bore 1484 cc conversion for Rotax 912S

I've been talking about getting a beater airplane to keep my occupied while I build. Screw that. Either I'm gonna build the CH701 or I'm going to abandon aviation and buy a couple of horses. This is silly.

I just got off the line with Wayne. I've got a 1484 High Torque engine reserved with my name on it now. You guys keep after me now and I'll get this son of a bitch flying before life slips away completely.
Can I get an Amen
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Re: Big Bore 1484 cc conversion for Rotax 912S

Amen
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Re: Big Bore 1484 cc conversion for Rotax 912S

Dan, You won't regret the BigBore, now you just have to burn that midnight oil to get er finished.
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Re: Big Bore 1484 cc conversion for Rotax 912S

BTV wrote:CG thanks for the tip. I will definitely pick some up and anything else Hal recommends.

I've been using the tempest filter. I wonder if it is any better than the Rotax. What is the Cat filter Hal recommends.


Donaldson P551763 My local dealer had one in stock, I ordered in another dozen, about 10 bucks ea.
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Re: Big Bore 1484 cc conversion for Rotax 912S

Hal flew up from Elko today, to do another installation on another S-7, in Blackfoot, about 30 miles from my place. I had just flown into a rancher's place about 50 miles away, (straight line, almost a 2 hour drive due to mountain ranges being the way) to talk about a solar system for his place, landing in a gravel pit across the road. 2 hours later (mission accomplished, sold!) I blasted off and stopped by to see how things were going.Image

He was already half done, and by now I'm sure it is flying. This 7 had the 80 HP Rotax, and the performance difference will be huge. He went with the same setup I have, (1484, low comp pistons) and I assured him that at our field elevation REGULAR mo gas is all we need and in fact all I now use. E10? Bring it on.... I've been using it also, when "on the road". I'm expecting a flyby tomorrow AM as Hal heads back to Elko 8) ImageImage We had 3 S-7's parked outside, and two more in the hangar still under construction :shock: Image
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Re: Big Bore 1484 cc conversion for Rotax 912S

If Hal and Wayne keep this up we are going to have a flyin reunion of Zippers :). Of course all others would be welcome.
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Re: Big Bore 1484 cc conversion for Rotax 912S

Any more news on the fixed pitch props courier guy? Mine will of course be different than the S-7 props but I'm willing to pay if they work out as well as I expect.

There's a guy I know in Mississippi with the Kool prop on his and he's very happy after taking off his Warp Drive and throwing it away.
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Re: Big Bore 1484 cc conversion for Rotax 912S

I'm interested in the fixed pitch prop information, too.

I'm building another Kitfox IV and planning the same low compression Zipper mod. So the ultralight IVO I have won't cut the mustard...
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Re: Big Bore 1484 cc conversion for Rotax 912S

Hal put the Prince prop on his bird right before he left for Blackfoot, then took it off. He will be sending it back to Lonnie to have the tips shaved in order to gain some RPM. He likes to see 5400 static, and he could only spin it up to 5160. I think most Rotax operators shoot for about 5200 static? I know I do, but Hal has very specific reasons why he does his way. I, with my low comp Zipper (Hal has the Hi comp) could only get 5,000, barely. Even at that low RPM, the Prince performed great on takeoff and climbout, and cruise. We are both at very similar altitude, around 5 K. The good thing is now Lonnie has even more information, so my shortly to be delivered prop should be pretty well dialed in. Still waiting on the second Catto, it'll get here when it get's here I'm told. These prop wizards need to do their thing in peace and not be hassled with phone calls and emails, thank God I have the still excellent Kiev prop in the meantime, so I can afford to be patient :shock:

Speaking of Kiev, things are really heating up over there, Putin indirectly started this whole prop thing I'm now involved with, go figure, maybe the prop company is business as usual but hard to imagine how it could be and I want some prop alternatives.
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Re: Big Bore 1484 cc conversion for Rotax 912S

courierguy wrote:Hal put the Prince prop on his bird right before he left for Blackfoot, then took it off. He will be sending it back to Lonnie to have the tips shaved in order to gain some RPM. He likes to see 5400 static, and he could only spin it up to 5160. I think most Rotax operators shoot for about 5200 static? I know I do, but Hal has very specific reasons why he does his way. I, with my low comp Zipper (Hal has the Hi comp) could only get 5,000, barely. Even at that low RPM, the Prince performed great on takeoff and climbout, and cruise. We are both at very similar altitude, around 5 K. The good thing is now Lonnie has even more information, so my shortly to be delivered prop should be pretty well dialed in. Still waiting on the second Catto, it'll get here when it get's here I'm told. These prop wizards need to do their thing in peace and not be hassled with phone calls and emails, thank God I have the still excellent Kiev prop in the meantime, so I can afford to be patient :shock:

Speaking of Kiev, things are really heating up over there, Putin indirectly started this whole prop thing I'm now involved with, go figure, maybe the prop company is business as usual but hard to imagine how it could be and I want some prop alternatives.


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Re: Big Bore 1484 cc conversion for Rotax 912S

Putin indirectly started this whole prop thing I'm now involved with


Dennis Kucinich says the US’ CIA stirred up the trouble in Ukraine
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Re: Big Bore 1484 cc conversion for Rotax 912S

Hal came and went, and today on the way back from across the desert, I stopped by Joel's to get his impression of the change.

This is a short tail S-7, and built light, as in 644 lbs. =D> Well I guess it's 641 now....as the 1484 is that much lighter. Joel said it held a 1500 FPM climb, not a zoom, but held it. 70 degrees or so and 4500' field elevation. He was real stoked about it, though he only had a few around the patch flights in it so far. I told him it will take a few hours to really get the subtle changes, like that mid range torque increase, and the instant response when hitting the throttle. Hal had some iffy weather in the AM, but made an end run around it, it almost looked like it was going to snow at my place! I flew another 4.6 hrs and got in another new 9600' landing today, so you know I am liking mine. :mrgreen:
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Re: Big Bore 1484 cc conversion for Rotax 912S

Been Flying the Big Bore 1622 now for over 100hrs and about 50hrs with the new High Performance Cam, All has gone so well I Only had one Complaint, I had to small of a Prop a 70" Warp, So Just installed the New 75" WhirlWind this past Thursday and been tweaking the pitch, Now have it dialed in for what I want (Climb) It is Fantastic and currently have it set at a pitch of 17.25 degree's at the Whirlwind recommended check locaton which is at 12" from the tip. Hard to tell just how much better as Temps, DA, etc very from day to day but it seems like about a 200-300' min increase, Will be flying it to the High Sierra's flyin this coming week for a good shake down and test.
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Re: Big Bore 1484 cc conversion for Rotax 912S

Forgot to post the pictures [SMILING FACE WITH SMILING EYES]
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Re: Big Bore 1484 cc conversion for Rotax 912S

Well, I am waiting on both Prince and Catto, should be any day now, for their second generation (78") props to show up. It sure would be nice if one of them showed up before the fly-in, and I don't have to work and the WX is OK. Absolutely perfect the last few days here, as in doesn't get any better, sure hope it holds.

I had a takeoff out of Alpine Wy. yesterday, (about 6K) and held it pretty much full throttle, knowing I was going to eyeball a nearby 8400' ridge for an LZ. I rarely use full throttle, and when I do I very soon throttle back, I'm happy with a 3 or 400 fpm climb and the resultant much lower fuel burn. But this time I let 'er rip.....damn, I was over 8K before making it all the way across the lake, and it just seems to want to keep climbing very strong even at the higher elevations, and effortlessly. And that is with the little 70" Kiev =D>

Landed the ridge BTW, another site where if I step back to get more of it in, I step down, and soon the perspective is all screwed up, this picture doesn't do justice to the site, though it does have a nice background. Image
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Re: Big Bore 1484 cc conversion for Rotax 912S

We upgraded to 75" whirlwind from the 70" or 72" (don't remember which). The airplane is a completely different animal with the longer one. Highly recommend it. Stock engine. Ronnie Smith is working on digging up a core to build a big bore up for us. Hope to have it by Spring.
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