SDS Aero Billet Valve Covers for PV Lycomings

Discussion in 'Supplier / Manufacturer Announcements' started by rv6ejguy, Oct 20, 2017.

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  1. Oct 20, 2017 #1

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    lycvc1.jpg

    Just finished a roughed out prototype and playing around with scribing, engraving and laser etching. Will be refining the model and tool paths trying to take some more weight off for the production parts. Will be checking fits on a head tomorrow to refine the inside shape better and check clearance for higher rocker ratios used in some race engines.
     
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  2. Oct 20, 2017 #2

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    laser.jpg

    Tried out some test samples with laser etching here.
     
  3. Oct 20, 2017 #3

    Toobuilder

    Toobuilder

    Toobuilder

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    You're killing me with this stuff Ross.

    ...OK, how much?
     
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  4. Oct 20, 2017 #4

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    Not sure yet. They must have a 12 step program somewhere for those with Bling addictions though...
     
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  5. Oct 20, 2017 #5

    Toobuilder

    Toobuilder

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    As an enabler of such addictions, you better hope not, Big Daddy.
     
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  6. Oct 20, 2017 #6

    TFF

    TFF

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    Nice looking. Surprised not more on the market really.
     
  7. Oct 20, 2017 #7

    Toobuilder

    Toobuilder

    Toobuilder

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    There is actually a pretty good selection. The airboat guys love them.
     
  8. Oct 21, 2017 #8

    TFF

    TFF

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    Weird, so few I have seen, especially with the Glam you would think at Oshkosh. Auto world, they would have been required bling until a nostalgia era would "bring" steel back.
     
  9. Oct 21, 2017 #9

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    There is at least 4 other companies currently producing aftermarket aluminum or magnesium Lyc VCs.

    We're trying to find a good balance between looks, price and weight (like our flywheels) plus we'll have one other advantage I have not talked about yet which I think will make them more desirable than what's out there now.
     
  10. Oct 21, 2017 #10

    pictsidhe

    pictsidhe

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    Nice bling. Does anyone do gold plated aerobling?

    It seems to have been a while since your RV hours incremented?
     
  11. Oct 21, 2017 #11

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    I'm working 10-14 hour days, 6 days a week. We're working on several new products which need to get out soon.

    I hooked up the heater system on the RV last weekend and wanted to get up a couple nights ago but we had a severe wind storm with 60 knot gusts. No need to be up in that. Had some snow the week before.

    The plane is just waiting for me to find some time.
     
  12. Nov 22, 2017 #12

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    lycvc22.jpg

    Ran a few pre-production parts yesterday with the revised toolpaths. Doing physical evaluations this week and evaluating powder coating and anodizing options now. Probably ready to run first production batch in early Dec.

    You can see a short video of some of the machining steps here: https://youtu.be/qiqaIiyZyWo
     
  13. Dec 12, 2017 #13

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    A couple new photos showing anodized covers with laser etched and CNC scribed logos:

    lycvc41sm.jpg lycvc42sm.jpg

    O-ring sealed:

    lycvc28sm.jpg

    We have these down to 154 grams, about 15 grams lighter that the common aftermarket chromed steel VCs.
     
    Last edited: Dec 12, 2017
  14. Dec 12, 2017 #14

    Tantrum1

    Tantrum1

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    Alright, now lets see a O-200 cover.. maybe with a couple cooling fins in them for my race engine!
     
  15. Dec 12, 2017 #15

    rv6ejguy

    rv6ejguy

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    No plans at this time for O-200 ones. This is quite an expensive and time consuming exercise to get to this point. We need to go after the biggest markets first.
     
  16. Dec 12, 2017 #16

    Marc Zeitlin

    Marc Zeitlin

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    Is that a machined O-ring groove with a real temperature resistant and oil resistant O-ring in it?

    These would be worth it for the ability to eliminate the ridiculous Lycoming design of a gasket with no hard stop and some unmeasurable screw torque alone, even without the weight loss (however minimal) and aesthetics.

    Tell me that the flange is very stiff and that tightening the cover screws compresses the O-ring correctly to effect a REAL seal without leakage...
     
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  17. Dec 12, 2017 #17

    Toobuilder

    Toobuilder

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    Ross has indicated that the O-ring is Viton and available off the shelf if a replacement is required.

    The flange "looks" to be about .250 thick, so the ability to smoke it down and forget it is a big plus.
     
  18. Dec 12, 2017 #18

    rv6ejguy

    rv6ejguy

    rv6ejguy

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    We addressed all the gasket, bolt concerns with the original design here. Flange is .188 thick and with 6 cap screws, it tightens down fully flush with the head surface. We also use the more modern inverted V type groove rather than a simple "U" groove for the O-ring so it can't spill out.
     
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  19. Dec 12, 2017 #19

    Toobuilder

    Toobuilder

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    OK, that answers the reason for the plunge hole at the top/right of the inverted cover in post 13.

    Slick.
     
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  20. Dec 13, 2017 #20

    Dan Thomas

    Dan Thomas

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    Good idea.

    I worked for 12 years developing remanufacturing procedures and training employees in those procedures in a wide array of pneumatic control systems used for heavy equipment braking and other uses. O-rings are the defacto gasket in most of those units, and those that use gaskets are troublesome. Gaskets will leak air right through themselves unless you buy special high-density stuff. Gaskets shrink, they take a set, they crack or split, and they cause warping of the metal parts. On Lycs and Continentals the silicone VC gaskets have been the only option, and even then you want to watch them. With O-rings, you have many material options. The old Buna-N works well as long as things don't get too hot or cold. Viton was an improvement, but I saw some heat and oil issues in compressors with them. Silicone is great as long as it isn't required to slide much; its mechanical strength is low. There are several newer o-ring polymers available now that show promise. https://www.marcorubber.com/o-ring-material-quick-reference.htm

    I wish aircraft and aircraft equipment manufacturers would start building more things with O-rings instead of gaskets. Magneto flanges are an excellent example of gasket trouble; just try to adjust the timing on a mag that hasn't been moved in a few years. The gasket will probably tear, and if you don't see it you have a leak. Vacuum pumps, flange-mounted alternators, or anything that uses the AN900 copper crush gaskets. Carburetor drain plugs and inlet screen fittings. We're finally seeing o-rings on newer fuel injection servos.
     
    Last edited: Dec 13, 2017
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