Backcountry Pilot • High(er) HP O-300

High(er) HP O-300

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High(er) HP O-300

I've been pretty quiet about this little project, but for the last year, Chris Collum of Airworx and I (mostly Chris LOL) have been working toward the development of an STC to run 9:1 pistons in the O-300.

I know some folks are running a similar set up now, but this will be the first "legal" path...

The first shakedown run on the stand was completed yesterday, with another 10 + hrs of running on the dyno ahead of us. The jugs have to seat a bit more, but the initial test run showed 164 HP, which is pretty respectable for an O-300. Chris feels that once the engine is a bit more broken in, we should see just over 170HP.

STC will be a long long (long) way off as there will be a bunch more testing to do (and I have to get the airplane its going in built LOL) but this will be a really interesting (and dramatically cheaper) alternative to the Lycoming. STC will hopefully cover the O-300s/145 and will be available at OH (must be completed by Airworx) but we're still at the beginning of this journey.

The key to a good flying backcountry 170 is weight and CG. With only a 2200 gross, we must keep an eye on the scale if we're going to have a useable, if not nicely flying bird. I've seen some reports here lately of extremely heavy 170s, with some going so far as to stuff insane amounts of lead in the tail. Not what we want to do at all…

Before I took it apart, the bird had a starting weight of about 1350#. She’s gutted now, with about 150# in the trash, so she’s gonna be light for sure. The build will be simple, but will have a Sportsman and WingX, so it should pop right off the ground.

The O-300 itself weighs around 5-10 lbs more than the LYC O-360 but hung on the 170, has a slightly further aft CG, which on these “utility” style birds, is important. With no C/S prop or gov, the high HP O-300 setup will be lighter than the Lyc and have a much much better CG. The Cont IO-360 is not a wise option so not really worth discussing, but for ref, that setup is about 65 lbs heavier. (Yikes)

Of course if more power and speed is what you're after, nothing is better than the Lyc STC. The last 180 HP A1A Airworx built for me dyno’d just under 200hp… Impressive for sure.

The reality is that with a fixed pitch climb prop (even with more ponies) we're still probably going to be a 90-100 mph turtle. In contrast, w/ the C/S prop and the big motor, the 180HP 170B is a 135-ish mph bird… can’t compare… but for mucking about locally, the lightness and simplicity should be a really interesting alternative… a huge fun quotient for a relatively cheap buy-in.

The really exciting part about this project will be the cost. No idea about number$, but the engine should be close to the same cost as a standard O/H with only the paper being the additional expense. This means no “kit” to buy, no cowl or nose bowl to modify, no cheeks to install, no panel modifications, no expensive composite prop to mortgage your house for, etc etc etc… Less power for sure, but this is an engine swap that might take place over a long weekend rather than over several months... We can argue over numbers, but in some cases, this could be a savings of the cost of buying a 2nd C170B over an IO-370 upgrade! That delta may be mean a simple glass panel, an engine monitor, a sportsman, some Bushwheels, and plenty of gas to putter about.

Not much more to say now, and I'm certainly no engine expert. If you are interested in getting tangled up in the weeds on the tech side or have questions, you can follow Airworx on FB... That said, I'll report back over the next year or so as things progress, so stay tuned.



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Last edited by Bigrenna on Fri Jan 06, 2023 2:03 pm, edited 1 time in total.
Bigrenna offline
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Re: High(er) HP O-300

Thanks for posting this! I've been following along since I first heard that Airworx was pursuing an STC. Having owned an O-300 powered 172A for 34 years (son has it now), We both want more HP but can't swing the O-360 and its costs.
I am hoping to contact Airworx and see if I can get a visit to their shop since I will be down in that area in a couple of weeks.

One question: Did they flow match/polish the cylinders along with the higher compression?
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Re: High(er) HP O-300

This is exciting stuff! I've been waiting for the dyno numbers to be revealed.

Now I just have to cross my fingers that the STC is available by the time my old boat anchor starts making metal.

Thanks for putting in the work to make new things for our old airplanes. Not many people are doing it!
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Re: High(er) HP O-300

This would be awesome? The 0-300 is so smooth. I hope it happens!
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Re: High(er) HP O-300

Awesome. 9-1 still good for 91 mogas? It’d be really nice to have a ground adjustable composite prop available for these things…
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Re: High(er) HP O-300

One of the big differences in weight is the fixed pitch vs constant speed prop. I've been flying my XPMods STC'd 170 for 22 years now and have no regrets on performance, however the CG is further forward than I like, mostly because of the propeller and governor out front. Move the battery to the back and that adds several pounds of cable. Oh, and there's that lead brick in the tailcone. An MT prop would mitigate some of this weight and I could lose the ballast but that'll be $15K Eventually I will lose the vacuum pump and go electric with G5's or similar, etc. And all that costs MONEY.

It was a complicated, expensive conversion that works great. No regrets, it all made sense at the time.

This conversion is a phenomenally simpler way to get 80-90% of the performance boost I got without the complexity or the CG issues. No outward change in appearance. For what? 1/3 of the money? (my first uneducated guess) That's a HUGE difference compared to any other option available today. h

Bravo sir, and good luck. I look forward to seeing your progress.

Pete

What propeller will you use?
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Re: High(er) HP O-300

Greg,

That is a very cool project. I too am curious about the cost but obviously far less money than going with a Lycoming IO360. I am also curious how the 9:1 pistons effect engine longevity. I am also guessing Mogas is not an option the higher compression pistons.



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Re: High(er) HP O-300

This is cool, I wish it had been possible about a year or so ago, BIG savings on work required and costs associated.
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Re: High(er) HP O-300

Bigrenna wrote:
STC will be a long long (long) way off as there will be a bunch more testing to do (and I have to get the airplane its going in built LOL) but this will be a really interesting (and dramatically cheaper) alternative to the Lycoming. STC will hopefully cover the O-300s/145 and will be available at OH (must be completed by Airworx) but we're still at the beginning of this journey.



That is unfortunate. A serious limitation to the market for Airworx.
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Re: High(er) HP O-300

It’s cool to see people work on these mods to SAVE people money and get good performance, hopefully this will result in 170s and backcountry flying being more available to more people :)
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Re: High(er) HP O-300

This is a great initiative, if it could be combined with a lighter composite prop; fixed pitch or ground adjustable the "package" would/could be a fantastic combination in my opinion. :wink:
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Re: High(er) HP O-300

This will be a pretty awesome mod.
I owned a 170 for 10 or 12 years, and this seems like the low-cost way to more horsepower
that me & most of the 170 guys I knew were always looking for.
Some 170 guys (and Swift guys) did something similar back in the day by fitting C85 pistons.

Where are the 9:1 pistons being sourced?
FWIW Light Speed Engineering makes 9.4:1 pistons for the O-200 that might be worth looking at.
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Re: High(er) HP O-300

Just a quick update... the initial test run on the dyno showed 164HP at 2700 RPM. We expected to get a couple more ponies after the jugs settled in a bit more, but there were still a couple of tweaks we could do.

Today we got it back on the stand and gave it a run... Looks like she's gonna settle in at 175HP at 2700 rpm. Not too shabby for an O-300. :lol:

This should be a fun bird (if I can ever get it built).
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Re: High(er) HP O-300

This would be sweet. hope it all comes together.
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Re: High(er) HP O-300

Bigrenna wrote:Just a quick update... the initial test run on the dyno showed 164HP at 2700 RPM. We expected to get a couple more ponies after the jugs settled in a bit more, but there were still a couple of tweaks we could do.

Today we got it back on the stand and gave it a run... Looks like she's gonna settle in at 175HP at 2700 rpm. Not too shabby for an O-300. :lol:

This should be a fun bird (if I can ever get it built).


Think it'll hit 180hp if you remove the vacuum pump seen in the test video?
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Re: High(er) HP O-300

asa wrote:Think it'll hit 180hp if you remove the vacuum pump seen in the test video?


We took the vac pump off just after that video... she may gain a pony or two after we hit the 10+ hrs on the dyno, but it's probably right about where she's gonna be.
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Re: High(er) HP O-300

Bigrenna wrote:Today we got it back on the stand and gave it a run... Looks like she's gonna settle in at 175HP at 2700 rpm. Not too shabby for an O-300. :lol:


DANNNGGGG! That's got to be at least 75 more HP than mine is making... :lol:
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Re: High(er) HP O-300

Lycon sells the piston. Know a few guys running them for a while now. No big deal unless you make it one.
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Re: High(er) HP O-300

I know of a few that run those pistons in their 0-300 engines up here I have even seen a couple listed for sale stating engine has 9-1 pistons. Definitely add some get up and go and runs on 94 octane auto fuel
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Re: High(er) HP O-300

Greg,

Did you run this engine or any other stock 0-300 on the dyno before you did these mods? It would be interesting to see the difference of before and after.

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