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Superior Design= Superior Performance

Phone 403-671-4015

E-mail:racetech1@telus.net

Last updated Sept. 12/18

SDS CNC'd Billet Parts for Aircraft Engines

With our design and machining backgrounds, we've designed many top quality, custom machined parts with our machining partners to go with our systems. Below is a small sample of the over 33,000 CNC'd parts made over the last 20 years. Most are anodized for lasting appearance and corrosion resistance. In July 2017, we added a new partner for additional machining capacity to cut lead times, increase production rates and add capacity for our SDS Aero Products line. Our two machining partners have over 50 years of CNC machining experience.


Ordering

To place your order, it's best to email or phone us to discuss your individual needs. We'll get a list of all your details, colors, options etc. and then quote you. You can then pay by Visa or Mastercard, wire transfer or E-transfer for Canadian customers.

Phone 403-671-4015

E-mail:racetech1@telus.net


Lycoming Specific Parts

SDS Aero O-ring Sealed Induction Tube Flanges


CNC'd billet flanges bolt down flat metal to metal so there is no more flange distortion, no more leaky gaskets and no more loose bolts. These use an COTS silicone O-ring instead of the dated paper gasket.


Complete kit for 4 cylinder engines includes flanges, O-rings, support ring, silicone or rubber hoses and 2 constant tension clamps per tube. (gold anodized shown)


Red anodized


Clear anodized

Silicone hoses and O-rings are only provided for fuel injected engines. Carbed engines are supplied with standard rubber hoses and Viton O-rings.

Please specify carb or fuel injection, 1.5 or 1.75 induction tubes and flange color desired (red, gold or clear).

Please note that angle valve engines must have the induction tubes cut to remove the factory flange and install the SDS ones and then re-welded. On parallel valve engine induction tubes, the old flange can just be slid off and replaced with the SDS one as long as your max tube diameter is under 1.80 inches. Please check if you're not sure before ordering.

Price $60US per cylinder for Parallel Valve FI engines, $52 for 390/580Angle Valve FI engines with factory O-ring seals at the sump connection (no clamps or hoses needed) and $65US per cylinder for carb engines. Only sold in sets of 4, 6 and 8 pieces.

For Superior Cold Air Induction setups we supply 2 inch hoses. Be sure to mention if you have these. You'll have to cut and re-weld these tubes. We can't supply any constant tension clamps for the larger Superior hoses at this time.


Lightweight Billet valve covers for parallel valve Lycomings

Viton O-ring seal. No more leaks or loosening fasteners. Only sold in sets of 4, 6 and 8 pieces. The Gen 2 covers will fit both OEM Lycoming and Superior cylinders now. You may have to trim your baffling sheet metal to clear these covers as well.


Red anodized finish with laser etched logo.


Gold anodized above with CNC laser etched logo. About 20 grams lighter than popular chromed steel aftermarket covers. Available in gold, red or black anodized finish and a variety of powdercoated colors.


Above showing powder coated finish


Set of four, black anodized with laser etched logo


Hardware included with each valve cover. Price is $110US each in anodized finish. We can custom laser etch a logo on them for an extra $12 each (set of four) or $10 each (set of 6).


New Gen 2 covers now fit Superior cylinders as well as Lycoming

Video Installing O-rings on SDS Lycoming valve covers


Flywheels for Lycoming engines

Machined from 6061T6 billet, they are about 1 pound lighter than the stock Lycoming piece. Available in 5/8 and 3/4 inch drive lug versions with the 149 tooth ring gear. 8 7/16 ID, fits 320,360, 540 engines and most other clones. Available with SDS magnets installed $680US, without magnets installed $650US. Comes with ring gear installed. For O-360 with 3/4 inch lugs, Lycoming PN is 77579 or LW-16471. For O-320 engines with 5/8 drive lugs, PN 76628. Please check that these PNs are compatible with the engine model you have before ordering. Available with 122 tooth ring gear at $35 extra cost.

Video on our flywheels: Click here


SDS Dual Fuel Pump Modules


SDS dual pump module. The gold standard. Mounts twin genuine Walbro pumps. Anodized 6061T6 body resists oxidation and corrosion, 7075T6 fittings are double O-ring sealed (genuine Viton) for ultimate strength and reliability, straight flow path without restrictive banjo fittings. Mounts drilled for AN3 bolts- unthreaded, a variety of 1/4 NPT ports available for different fuel line connections and pressure measurement, stainless steel hardware. Price $600US with pumps for up to 300hp. $655US with pumps for up to 400hp. Weight as shown is 2 pounds 11.8 oz. Supplied with 4 1/4NPT plugs. No dealer discounts on these items. This is our original design and others have copied it now. Compare our pump module to our competitor's design which puts the fuel connections under mechanical stress when mounting.


Side view


Spark Plug Adapters


Long and short reach plug adapters. $15US ea for short ones, $18US ea for long ones.


Other CNC'd Parts


Boss for parallel valve Lycoming engines mounts EFI injector in original injector hole. Threaded adapters have 4 times the tensile and yield strength and many times the fatigue resistance of our competitor's 7075-T6 bodies at 400F.

New design top mount injector bosses for angle valve Lycoming engines. These have not been tested to fit on aftermarket heads such as ECI at this time. Our mounts don't require machining of the head as with another aircraft EFI brand. These parts are only sold with the purchase of a complete SDS kit.


Small style injector bosses available with steel or aluminum bases. Threaded for 1/8 NPT fuel inlet fittings. Suitable for Lycoming, Continental, Rotax and Jabiru installations. Require TIG welding to attach to induction tubes.


Production bosses in steel and aluminum for Jabiru, Rotax, Lycoming and Continental engines



Billet 80mm throttle body to replace Bendix RSA-10 and AFP FM-300 servos when converting to EFI. Horizontal mounting.

Air horn accepts 3.5 inch SCAT hose, 3.5 inch ID K&N filters or 3.5 inch ID Silicone hose couplers. 6061T6 construction, stainless steel shaft riding on sealed roller bearings, 7075T6 throttle arm, brass butterfly, accepts OEM Bosch TPS, O-ring sealed air horn to body and flange to sump. Under 2 pounds and only 3.625 inches high. Integral throttle stop. Stainless hardware.



Billet 45mm throttle body designed for engines in the 60-120hp range. Common applications would be VW, Conti O-100, O-200, Jabiru 2200, 3300, Subaru EA81, Suzuki 1.3/1.6, Rotax 912 etc. The body is 6061-T6, throttle arms are 7075-T6, shaft is 304 stainless and blade is brass. Arms are available for either vertical or horizontal mounting. Optionally mounts a genuine Bosch TPS. The engine side has an O-ring groove for sealing and is mounted with AN3 bolts. Air side snout is 2 inches OD to take common K&N filters or SCAT tubing. Weight as shown with TPS is 240 grams.

Here is a photo of the 45mm TB anodized

Our throttle bodies bolt up the the manifolds with no adapters like our competitor uses. Our designs are therefore lighter and more compact.



60mm generic throttle body available for engines up to 260hp.


Fuel block with integrated fuel pressure regulator. 1/4 NPT inlet, four 1/8 NPT outlets plus one 1/8 NPT port for fuel pressure tap


Fuel block for Lycoming engines mounts to rear baffle sheet metal. Comes with drilling template. Mounts with two AN3 bolts. 1/8NPT outlets and fuel pressure tap on back side. Side entry and exits for fuel in/out 1/4 NPT


Center mount fuel block for 6 cylinder Lycoming engines


Shown with -3 stainless braided lines connected


Fuel blocks for 4 cylinder Lycoming and Continental engines

Gallery


Fresh from the anodizer


Billet Lycoming valve covers. O-ring seal. No more squishing gaskets or bolts coming loose.

Video on our SDS billet valve covers


New fuel pump module blocks


Lycoming billet flywheels


Jabiru TB adpaters


Billet 80mm throttle body for Lycoming 540 engines


Lycoming fuel block


Rotax Hall sensor mount


Aircraft dual ECU box


ECU box


46 SDS Aero billet valve covers fresh off the mill


Les Kearney's Aero Sport IO-540 with dual SDS EFI EM-5 and SDS Aero billet valve covers


SDS 80mm throttle body on Barrett cold air intake


Crank sensor mount detail


SDS lightweight billet flywheel


Design and Production


CAD renderings during design phase of SDS Aero billet valve covers


CAD renderings of throttle body and injector mount


LS V8 throttle body adapter


CNC Machining


Most of our parts are CNC machined on Okuma, Haas and Mori Seiki equipment

https://youtu.be/xG03eReYIdA
Video of Haas VF2 machining SDS ECU boxes

https://youtu.be/yCYAX10wG2Y
VF2 machining SDS dual ECU boxes


Mori Seiki SV-500

https://youtu.be/qiqaIiyZyWo
Short video on Mori Seiki milling SDS valve covers


Partially machined flywheel


SDS Billet Parts | Home Page | Home Page | Product Specifications | Programming Basics and Installation Manuals | SDS Advantages | Price List/Shipping | Dealer List/Links | Tech Page/FAQ | XIC | Project Page | Sample fuel maps | Hardware | Aircraft | CPI |