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Submitted By:		gerken@us.ibm.com
Email List:		Kolb-List,Ultralight-List
Name:		Jim Gerken
Date:		Jan 22 2004
Subject:		Kolb Twinstar MkIII
Description:		Here are a few images of the nearly-completed BMW R100 installation on my '97 Kolb Mkiii. These images show the prototype exhaust system, which is being cut down systematically as power is being measured for each cut length. Final exhaust system will not need the ugly clamp, and will be HPC coated. Prop installed is Powerfin 66" 3 blade, pitched exactly as the old Rotax 582 would pull it static to 6050 RPM, giving an in-flight WOT level flight RPM around 6500 and 93 mph. So far, the BMW will pull it as-pitched to 5900 RPM static. I will pitch it properly for the new engine once R&D is done. One more exhaust change is planned, along with several richer main jet tests, and an ignition advance has been suggested. The engine is completely stock except for the air filters, exhaust and deep oil sump with custom pan cover/engine mounting plate/cooling fin. I estimate it will make 66Hp in final form. It is heavier than the Rotax 582 was although I cannot say yet by how much, but I've been told it is 25-30 pounds more. If that is correct, powerplant including all hardware, mounting plate, gearbox, extension and prop will be about 150 pounds. This does not include the additional weight of the required battery (15pounds), which is actually a blessing for aircraft balance since it is mounted in the nose. So forty pounds more to aircraft total. Forty pounds worth of fuel is 6.6 gallons, or about an hour and a half with the 582 at low cruise. The BMW will be quite a bit more economical so this should net out in a couple hours of operation each mission. Total project cost has not yet exceeded the amount I received from the sale of the 582 with 167 hours on it ($2975). Suggestions welcomed.
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