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Thread: Dual STI build log

  1. #261
    Senior Member
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    Dec 2017
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    Mapleton,UT
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    Default Re: Dual STI build log

    Making more progress with more questions answered this week. In an effort to help mitigate high oil temps we are going to try a heat-exchanger. Should help keep the water temps down on the ground, and help keep the oil temps down in the air. This was recommend to us from Edge performance. Thomas ran one on his engine. Dropped is oil temps 30-40 degrees and only minimal raise in water temps. Spoke with John and they are recommending on the 915 installs to run a lip extension on the bottom of the cowl. I think we are going to cut the cowl and extended the lip 1" to improve cooling. Intercooler is installed and moutning brackets made!
    This week I am going to work on getting the heat shielding and baffling done for the intercooler. Waiting on some Naca vents for the intercooler, and also for the intake. Due to the fact that I feel the 915 may be suffering from over-pressurizing the cowl, we are going to go smaller rather than larger naca vents for the intercooler/intake. Also when we add the lip to the bottom we are going to try and increase the amount of exit air, for the added air from the Naca vents. We are going to leave the cowl unpainted, so we can do some testing and hopefully help anyone else coming behind us. Also solved the throttle cable issues I was trying to figure out. I am going to go the route that Doug and Scott went and remove the spring and run a direct cable. Went with the Mcfarlane venier cable but they only sell it in a cable not a solid wire. Thought I would be able to run it into the bing 90 to mount to the throttle body but the cable is too thick to make the 90. With the cable so thick it should work going straight to the throttle body. Once I get it all mounted I will post some pictures that will make more sense. Worked on building a throttle arm and mount for the cable. Finished cutting the panel for the throttle cable and now hopefully my brother can get his done this week so we can get them off to the powder coater. Now its time to start plumbing the engine and as soon as I get my panel back start on wiring. At this point I am doing as much as I can but I seemed to be waiting on parts. Should hopefully in the next couple weeks also receive our new intake that mounts the injectors on the inside.....fingers crossed!




    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF
    N53TF

  2. #262
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    Dec 2017
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    Mapleton,UT
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    Default Re: Dual STI build log

    Slowly but surely....... Progress update.

    I have been working on ducting for the inter-cooler and heat-sheilding the inter-cooler. Inter-cooler can be an interheater if not done correctly. Trying our best to make sure we keep the heat from the engine from heat soaking the intercooler. Only thing left to do on the heat shield is install some heat shield. I think I am going to use the HP insulated heat shield to line the aluminum. We will also use it to protect the fiberglass bottom naca to keep the turbo from cooking the cowling. I have used this stuff next to the turbo on my snowmobile and it has held up when the turbo starts glowing. Naca vents are also going in for the intercooler and intake to the turbo along with radiators. Installing therm with some fiberglass resin. This week hoping to get the panel back from powder-coater and get it off to get silk screened. At this point just hoping to continue to make progress and keep figuring things out. OH.... Big news! Third time is the charm. FAA kept send back the registration but just recently received the registration back from the FAA! They are both officially registered.










    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF
    N53TF

  3. #263
    Administrator DesertFox4's Avatar
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    Arizona
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    Default Re: Dual STI build log

    Congrats on the registration Dustin and way to persevere. Progress looks really good. Enjoying the build photos. Thanks for sharing.


    DesertFox4
    Admin.
    Building 7 Super Sport
    912 ULS Tri-gear

  4. #264
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    Default Re: Dual STI build log

    More cowling work this last week. Installed a lip right before the radiators to ramp airflow up into the radiators versus around the bottom. I took compressed air and tried to simulate airflow and found most air was flowing underneath the radiators. Also worked on baffling around the radiators to keep airflow going into radiators. Also worked on getting exhaust cut and cowling trimmed. Need to weld in bunge for the A/F ratio sensor. Stinger needs to be loose to install the cowl and pivot in-order to get ducting up and over the radiators. Access to the t-clamp should not be a problem, as I will need to loosen the t-clamp so stinger can pivot when removing bottom cowl. I think if I opened up the exhaust hole more I may be able to remove bottom cowl without loosening the stinger, but for now I think I am going to keep it as is. Still thinking on temps and keeping things cool, so after seeing others results by adding the bottom lip, I decided to drop my lip down. Added 1.5" to the bottom lip and I left it long. This should increase lower pressure and it also improved volume of "exit" air. Also reinforced the bottom lip to keep it from moving under higher speeds. Powered coating of the panel turned out good. I used lab metal to fill in rivet holes and after powder coating so you cannot see them. Never got a picture before I dropped the panel off to screen printing company that a local avionics shop uses. They are 1.5 weeks out so I think I am back to cowling work. I have lost track but I think I am literally over 50 times of removing and installing cowling This week hope to finish camlocks now that I am done needing to check and recheck cowling.









    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF
    N53TF

  5. #265
    Senior Member efwd's Avatar
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    Yorba Linda, CA
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    Default Re: Dual STI build log

    Nice Dustin. Your modifications look well done. I too have to loosen my stinger.
    Eddie Forward
    Building
    SS7, 912iS, Garmin G3X

  6. #266
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    Dec 2017
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    Mapleton,UT
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    Default Re: Dual STI build log

    Quote Originally Posted by efwd View Post
    Nice Dustin. Your modifications look well done. I too have to loosen my stinger.
    Thanks Eddie! Glad you are out flying and enjoying your bird! I keep telling myself its worth it......20 times every morning.
    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF
    N53TF

  7. #267
    Senior Member
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    Dec 2017
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    Mapleton,UT
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    Default Re: Dual STI build log

    Cowlings....cowlings.....cowlings. More work on the cowlings this week. I got called out to work and I thought I would be traveling for most of the week. The schedule changed so it was day trips for most of the week. The wife decided to take the kids to Logan to visit her sister so I was able to log some more time! I got the panel back from the screen printer and it turned out good. I am realizing building a plane is like building a house. There are lots of imperfections that you just have to accept and move on. Trying not to look back but look forward. My fingers are raw from installing the cam-locks. Wow those take a lot of time. I can't believe how much work the cowlings have been along with the camlocs, glad I got them all knocked out this week. My work schedule this coming week looks like I have a few good days for building this week that I am hoping to finish plumbing the engine and then I think I have finally reached the daunting job of wiring. I installed the panel and throttle cable installed. I am please to report that the throttle cable works great. Thanks Doug and Scott for help on this! The only thing is I had to use two graduated sleeves from the rotax 912 throttle cable attachment. In so doing the bolt is not long enough into the nylon nut. I have ordered an all metal lock nut and a low profile lock nut to try. Other than some more finish sanding and painting the cowls, which I am not going to do until we fly, they are finished!















    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF
    N53TF

  8. #268
    Senior Member aviator79's Avatar
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    Dec 2016
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    Los Alamos, NM
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    799

    Default Re: Dual STI build log

    Quote Originally Posted by Shadowrider View Post
    #NACAFox
    --Brian
    Flying - S7SS

  9. #269

    Join Date
    Jan 2017
    Location
    Twin Falls
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    10

    Default Re: Dual STI build log

    Gosh darn that is sooooo cool! You are going to need a step ladder to get into her, and then a mirror on the skylight to see what to do next!!!! I only have 26" tires for mine and expect that she would rather have the 29" as shown, when said and done! Thanks for sharing the passion of the hobby.

  10. #270
    Administrator DesertFox4's Avatar
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    Default Re: Dual STI build log

    Great progress Brian. Not sure how I missed your last update but caught up now thanks to Michaels post. Thanks Michael.👍


    DesertFox4
    Admin.
    Building 7 Super Sport
    912 ULS Tri-gear

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