Aircraft Fuel Injection/ EFI
We have been supplying the experimental aviation market with engine management systems now for over 21 years. We offer aviation specific software and hardware for popular experimental engines and we fly what we sell. We are involved with several kit manufactuers, engine OEMs and alternative engine suppliers in joint R&D programs and in product supply.
We have provided aircraft EFI systems for BMW, 3, 4 and 6 cylinder Suzuki, Continental, Lycoming, Franklin, Jabiru, Rotax, Saturn, Subaru EJ22, EJ25, EG33, EA82, EZ30, EZ36, Rotorway, Toyota, Hirth, HKS, Honda Fit, Honda V6, Rover/ Buick, Verner, VW, Jaguar and Mazda engines. These have accumulated over 325,000 flight hours on hundreds of aircraft and military UAVs all over the world in the last 21 years. Land based systems have accumulated an estimated 25 million hours of operation under widely varied and sometimes severe conditions, including the famous Baja desert races with extreme heat, pounding G forces and punishing vibration levels. We have been flying an RV6A powered by a turbocharged Subaru EJ22 engine for product development purposes now for 11 years. We were the first to have a Gold Championship win at the Reno Air Races with EFI in 2010. We have approval with the UK LAA on the Titan T51 and RAF 2000 gyrocopters and are working with customers in the UK on additional approvals for other experimental engine/airframe combinations. Racetech/SDS has more aviation experience with EFI on a wide variety of engine types than any other company and is the leading supplier of aftermarket EFI/EI systems for experimental aircraft worldwide. Much R&D is now focused on aviation specific improvments for traditional air cooled aircraft engines such as Lycoming and Continental. As of 2012, the aviation market has become our primary one, supplanting the automotive side. We're the only company currently manufacturing dedicated, dual redundant EFI/EI systems specifically designed for legacy, Experimental aircraft engines. Watch this page for the introduction of new features under current development.
Turbo Subaru powered RV6A and RV7. Both equipped with SDS EM-4 engine management systems
Turbo Subaru RVs in formation
Here is a takeoff video of Randy Crother's Turbo STI Subaru powered RV7A. SDS EM-4 4F equipped: http://www.youtube.com/watch?v=om1GUJ5m1nY&feature=channel_page
Jeff Ackland's LS V8 powered P85 is equipped with an SDS EM-5 8D engine management system. Now test flying in Kansas.
First flights video
Ground running, takeoff, low pass and landing
Jan. 15/15 Service Bulletin Regarding Vertical Power VP-X and SDS
It has come to our attention that the VP-X electronic switching/ circuit breaker box does not use average current draw over several seconds to trip breakers like conventional thermal breakers do. It may trip during normal operation due to peak current transients over only a few milliseconds. This can lead the pulsing current of the ignition coils and injectors to trigger the breaker far below nominal current levels. We believe this could cause a serious flight safety issue and engine stoppage. Be sure to set the breaker values on the VP-X far higher than the nominal current draw on these circuits. Be aware that average current draw can increases with rpm and load so ground running may not allow complete testing of this condition if static rpm is lower than flight rpm and engine shutdown could occur in flight. Breakers are to protect the wiring, not the device. We recommend each 4 cylinder coil pack have a rating of at least 15 amps assigned when using the VP-X, each 6 cylinder coil pack at least 20 amps, 4 cylinder injector power at 15 amps, 6 cylinder at 20 amps and 8 cylinder at 25 amps. These are only recommendations, use this information at your own risk and these values should be thoroughly tested prior to flight at WOT and maximum rpm the engine will see in flight.
Oct. 20/15 Service Bulletin Regarding Thread Sealant on Fuel Fittings
RTV (silicone) must NEVER be used to seal threaded fuel fittings. We recommend Permatex High Performance Thread Sealant for use on pipe thread fittings. This must be applied SPARINGLY to ONLY THE MALE FITTINGS, NEVER THE FEMALE ONES. Once sealant is applied, screw the fitting in until tight. Never unscrew fittings without throughly cleaning all traces of sealant from inside the fittings and threads before re-assembling as this can dislodge sealant which can clog passages further downstream leading to possible fuel starvation. Never apply sealant to joints with flat crush washers or O-rings.
These products do not conform to any recognized set of standards or certifications for aviation applications.
This ECU is not waterproof and will not function as designed if moisture invades the enclosure or power/ ground connections are interrupted. Failure of this unit may result in a complete loss of engine power.
Use of these products on amateur built/ experimental aircraft is at the discretion of the buyer who accepts full responsibility for any consequences resulting from its use. Since Racetech Inc. cannot control the installation, programming, application environment or use of its products, we accept no responsibility for damage, loss or personal injury resulting from the use of SDS products. By using SDS products, the user understands and accepts this.
If any user does not agree to this disclaimer, they may return the system/ parts in new condition for a full refund.
Cheap Chinese Ripoffs
It's come to our attention recently that a company in China is selling EFI systems named SDS. This same company has also plagiarized ad copy and technical content directly from our website. Be aware that they are not affiliated with us in any way.
Basic components of distributorless EM-5 4F aviation system shown with Subaru coil pack
How good is the spark on SDS ignitions some might ask? Here's a photo of an actual, badly oiled up plug removed from an SDS equipped engine. The ignition was still firing this one consistently with no misfire.
Photo of aircraft 3 1/8 panel mount display head (backlit). With V17-25 software, has 4 gauge modes to display, manifold pressure, rpm, engine temperature, induction temperature, battery voltage, fuel flow, injector duty cycle, throttle position, acceleration enrichment, mixture knob position, ignition timing and O2 sensor voltage. Also displays error codes for sensor failures, check engine light feature and allows full programming of the system in flight.
Dual fuel pump module with integrated filter. The gold standard for aircraft fuel pump modules. See more info at the bottom of the page or click here pump module.
More info here: CPI
Lycoming 320/360 ignition kit includes Magneto cover, single or dual Hall sensor and mount, hardware, automotive plug adapters (1/2 reach) and plugs plus drilling block, drill and tap to mount magnets into OE flywheel, panel mount kit, MSD 8.5mm wire sets and wiring harness also included (not shown). Fits engines with 8 7/16 ID flywheel only. $1185US. Wiring harnesses can be custom tailored to your needs and any items not desired can be deleted from the kit. Note, you must drill and tap your own flywheel for the triggering magnets.
Coil mount kit for 4 cylinder Lycoming engines. Mounts to top rear of crankcase, inside of baffling.
We have more parts currently under development for the Lycoming kits for a wider range of fitment and coil mounting options. Watch this spot and the CPI Page for more information.
Because people often want different parts or to delete some parts from kits, we cannot put every combination with pricing on our order pages. Please contact us so we can finalize what parts you want, wiring harness lengths, preferred terminations and shipping costs: E-mail:email@example.com
Advantages of SDS Over OE EFI Systems in Aircraft
While there are many automotive engined homebuilt aircraft flying with the OE computer controlling fuel and ignition successfully, many users may not be aware of some potential pitfalls of using these systems. Many OE computers can either shut off the injectors if certain things fail such as a water temperature sensor to protect the engine from a perceived or real overheating condition or go into a very low power limp home mode. Either of these scenerios mean that you are coming down in an aircraft. The designers of these automotive ECUs did not take aircraft use into account during the design phase obviously. Their considerations were likely as follows, in order of importance: 1. Reliability- keep the engine from destructing ( shut the injectors off if necessary), 2. Emissions, 3. Fuel economy, 4. Driveability, 5. Power. Fortunately modern EFI systems, sensors and ECUs are very reliable, generally speaking. Just be aware, that as on your Continental or Lycoming, anything CAN fail equally so on your automotive/EFI conversion, making you an unwilling glider pilot.
Many people have spent countless hours trying to unravel programming code on OE ECUs for use on aviation applications, to undo unsuitable code or responses or security interlocks sometimes successfully, sometimes not. Others wonder what the ECU might do when certain sensors or inputs are modified or disconnected, especially many of the tied in chassis sensors on modern systems, not to mention security and digital key interfaces. What some people have attempted to do in dozens or hundreds of hours with often unknown consequences using OE ECUs can generally be done in minutes with SDS. You know exactly what the system will do without any hidden secrets or repercussions. All OE ECUs were designed to use an O2 sensor for closed loop feedback of the air/ fuel ratios at part throttle. As such, they may not be very suitable for use with leaded avgas. SDS does not require an O2 sensor at all.
People using OE systems often have to use the factory car wiring harness which obviously was not designed to fit their airplane. They try to strip out wires which are not needed, lengthen this, shorten that. Usually they just have a big, stiff, heavy, ugly mess on their hands. With SDS, we build a custom, lightweight, reliable harness for your installation. We can leave connectors off for easier firewall passage and can even provide a harness with no pins on so you can custom tailor each cable yourself. We use tinned wire on all our harnesses so it's not subject to the oxidation that you see in many OE automotive harnesses over time- even inside the insulation.
Typical auto OE wiring harness
SDS wiring harnesses. Note separate harnesses for sensors, options and injectors
Disadvantages of SDS vs. Conventional Aircraft Engine Systems
The big disadvantage of EFI compared to a carb or mechanical injection and magnetos is that electrical power is required for the pump, computer, ignition and injectors. The likelihood of both the alternator and battery failing simultaneously is practically zero with standard aircraft maintenance procedures. Generally, a good battery will allow you to keep essentials powered for 20-90 minutes after an alternator failure permitting diversion to another airport. We consider proper gauges and/or warning lights to indicate an alternator failure to be very important. We have an ammeter, voltmeter, low voltage warning light and buzzer now on our RV6A and also added a backup battery in Feb. 2005.
Advantages of SDS vs. Conventional Aircraft Engine Systems
Virtually zero maintenance, lower fuel flows due to better mixture distribution, automatic mixture control, no carb heat, smoother running, no mag checks, no live mag issues, longer engine life due to proper mixture control and less bore washing are some of the major benefits of EFI.
Why should I consider SDS over other brands of EFI for my aircraft?
1. We have more experience than any other company in this field with an unmatched track record on many diffrent engine types including the 2010 Super Sport Reno Gold Championship winner.
2. Our basic designs are also used in automotive applications so we have a huge amount more hours and customer feedback to quantify reliability than aviation only sytems.
3. We fly what we sell and are actively involved with the aviation market.
4. Our systems are designed to keep the engine running at close to full power even with multiple sensor failures unlike many other systems which may shut the engine down or OEM systems which will go into a limp mode, not allowing enough power to maintain flight.
5. We have the best tech and customer support in the industry.
6. Systems are individually tailored for your engine with realistic base programs and custom length wiring harnesses (either terminated or unterminated for easier installation and firewall passage). You won't struggle making wiring or trying to start your engine like with most other systems which just come in a box.
Quick Aviation Q&A
Q. What about redundancy?
A. On twin plug engines, it is posible to retain one mag and add a fuel nozzle into the plenum as a backup. For pilots who are not comfortable with this idea, we can offer dual ECUs.
Dual board aviation ECU
New aircraft programmer internal programmer selector option for dual ECUs
Miniature toggle switch selects primary or backup ECU for reprogramming. Option available Oct. 30/15
Relay switch box for dual ECUs to switch injector outputs between primary and backup ECU
Q. How about low voltage conditions after an alternator failure?
A. The EM-5 ECU will continue to operate down to 7.3 volts as shown in the photo below when most other electronics and avionics have given up the ghost at around 9 volts
Dual Hall sensor pickup
Q. Are the aviation units any different from the automotive ones?
A. SDS was originally conceived as an automotive system so most of the electronic hardware is identical. The advantage of this compared to units developed specifically for aviation is that we have accumulated several million hours of operation due to the greater numbers in automotive service where conditions are usually more severe. Hardware differences would be things like the aviation programmer, coil packs, dual ECU box, crank sensors/ mounts are different. Software differences include MAP calibration in inches of Mercury absolute, revised acceleration enrichment code which also improves cold starting and special programmed defaults to help minimize the effects of sensor failures. We sell far more ECUs for aviation now than automotive so have blended all the lessons learned into all ECUs. Our strategy has always been to keep the engine running at near full power even with multiple sensor failures-especially important in aviation.
Q. What use is the mixture knob on an automatic aviation system?
A. We recommend the mixture knob be panel mounted in all aircraft to allow the pilot to make a mixture adjustment in case of certain sensor failures. This gives you independent control of the mixture from the programmer. Some pilots prefer to manually lean with the knob once cruise power is set also.
Q. How do I start to tune SDS on my aircraft?
A. All systems have a base map entered if we know your injector flow rate and engine displacement. The engine should start and idle for you first time. The mixture knob allows instant mixture adjustment +/- 50% so you can get a smooth idle right away while the engine warms up. By using the optional wideband air/fuel ratio meter kit which displays the AFRs directly in the SDS programmer screen, you can observe and correct the AFRs at each rpm point with the aircraft tied down while slowly advancing the throttle. Main programming only takes about 10 minutes for most engines. Programming for cold start can take longer as you must have the engine cold at each engine temperature to be able to observe and correct the values. As of Oct. 2014, 8 channel data logging to a PC is an available option.
Some useful tuning information here aimed towards Subaru installations but generally applicable to other auto conversions: Aircraft Engine Tuning Guide
Lycoming Engine Tuning Guide
Tuning guide for Lycoming installations
Low cost wideband kit. Imbedded controller, 4.9 LSU sensor, wiring harness and stainless boss $135. Simple hookup. AFR displayed in SDS programmer. Highly recommended for tuning your SDS. No dealer discounts on this item.
Operation on either 100LL or Mogas is possible as no O2 sensor is required for operation. Automatic mixture control with altitude is standard as is the option to lean manually with the standard mixture knob. Many people prefer to manually lean via EGT once cruise altitude and power is set.
These systems are designed to use either the factory injectors or other standard automotive style injectors. We can supply injectors, pumps and regulators for most aviation applications.
We can supply systems for most 4, 6, and 8 cylinder automotive engine conversions. With SDS you have the option to manually lean or let the computer take care of things automatically. The EM-5 ECU has very low RF noise output and the elimination of carb heat makes operation simpler, safer, cheaper and lighter.
11/20/00 Knock Sensors on Aircraft
We don't usually recommend the use of knock sensors for engines powering aircraft. Generally speaking, air cooled engine have too much mechanical noise to be able to filter it out and "hear" the knocking. The second problem on opposed engines especially, is placement of the sensor. Most auto manufacturers spend countless hours determining optimum placement. You probably can't. The third concern is that the engine needs to actually knock before the ECU retards the timing which isn't good for it. Fourth, if you have the sensitivity set wrong, the ECU may retard the timing the full 25 degrees because of mechanical noise. You would lose over 25% power and this could cause an accident. Extremely high EGTs could also damage the engine. Finally, if you are running on 100LL and have reasonable manifold pressure limits, compression ratio and ignition timing, the engine won't knock in the first place. SDS does have knock sensor capabilty which may be useful for liquid cooled automotive engine conversions where factory knock sensors exist and careful setup procedures sre followed.
Wiring and Modifying Systems
We get many aircraft owners who either want to do their own wiring harness or modify our systems in some way. Over 75% of the people who do these things have problems or burn up the ECU. Our advice is DON'T. Unless you do wiring for a living, this is simply a bad idea. People want to put cannon plugs at the firewall to make engine removal easier. Why? There are only about 5 connections to the engine and four are quick disconnects. How often are you pulling the engine? Even a total hab case can disconnect these plugs in 10 minutes. Every time you add another connection, you add another potential place for a fault to occur. If it ain't there, it can't fail. Some of the wiring that we have had returned to us is an absolute joke for an aircraft. Downright dangerous. If you modify the wiring or the system, don't bother calling us if your pride and joy ends up in the trees. Our system has proven to be extremely reliable if installed and operated as designed. Please use your noggin here.
Here is an example of some actual aircraft wiring returned to us. This is just waiting to break or short to ground. Proper strain relief and insulation is imperative for reliability.
We highly recommend that all EFI harness wires be run separately from other wires which carry high current/ voltage or any type of pulsing current signals. It has been shown that wires run parallel to each other in this fashion can lead to EMI and inductance coupling which may cause ECU running problems. Generally run the EFI wires through one side of the firewall and all other wires through the other side.
Questair Venture Continental 550 twin turbo fitted with SDS EM-4 6F. At Reno on Sept. 20/09 this aircraft finished third in Super Sport Class Gold at 382mph. Sept. 2010- It wins Super Sport Class at Reno.
Mark Robinson photo
Mark Robinson photo
Mark Robinson photo
Thanks to Jan Peters at http://airrace.info/
See the Venture running at Reno 2008
Reno 2010 Super Sport videohttp://www.youtube.com/watch?v=LYCkgQXEwHU
Although we sell some parts for Rotax 912 EFI conversions, Racetech has decided not to sell complete Rotax 912 EFI kits directly that were we co-developing with EDge Performance in Norway. Please click the link below for contact information and more details:
Nov. 2014 photo updatesRotax 912 EFI Kits
More photos and development details here on the early system kits we offered back in 2007: Click here
Flight hour update from Norway, August 2014
"We have now been gathering a lot of hours lately on the SDS installations in Norway.
My VW had 96hrs. My Rotax has 250hrs total
Verner has 110hrs (Reports 100-150rpm and better fuel consumption)
SkyArrow 912ul has 300 hrs (Reports 250+rpm and better climb/cruise)
MCR-01UL has passed 80hrs (Reports 250+ rpm and 10KTS)
Jabiru 2200 Sonex 60hrs (250-350rpm, 15mph, and far better fuel consumption)
Dynali helicopter 10hrs.
Totally in 3 years we have accumulated ~ 961Hrs and climbing. No problems reported with the EFI.
Contact Thomas for any of your SDS needs in Europe and for Rotax 912 EFI kits:
Dynali H3 helicopter with Big Bore/ EFI Rotax 912 by Edge Performance AS
Some photos of Kapser Naef's supercharged Rotax 912 with SDS fuel injection:
On Evans Lake, BC
Kasper's plane beside Martin Mars water bomber
Kasper with SDS equipped Rotax 912S on his trip to the Yukon
We have supplied more systems for aviation Subarus than any other company and of course we also fly our own Subaru powered RV6A.
We have aviation specific SDS products to make replacement of the twin TEC units on NSI and Crossflow Subaru installations easier. A Hall Effect sensor and mount is now available for Subaru EJ series engines. This will bolt into the existing OE magnetic sensor location, permitting magnet mounting on the crankcase side of the OE crank pulley. We have an ECU internal driver system now available for STI and EZ30 COP ignition systems.
Subaru EJ/EG series Hall sensor and mount. Bolts onto stock magnetic sensor location. Applicable to EJ22 and EJ25, STI, EG33 engines $126US.
Hall mount installed on Subaru EG33 engine
For Subaru EA82 MPFI, EJ22, EJ25 and EG33 engines, we offer a version of our proven F system to control both fuel and ignition functions. These are calibrated in inches of mercury absolute and are suitable for both naturally aspirated and turbocharged engines. We have supplied systems for MPFI EA81s and ones which have been modified with injectors mounted down low in the heads. Please note, we cannot supply the OE style injector plugs if you are using the factory Subaru injectors on EJ and EG series engines.
We can drive EJ255 (STI) and EZ30 coil on plug units directly out of the ECU if desired (below).
Standard 4F coil pack supplied to run most 4 cylinder engines. Two packs required for dual ignition.
Late model EJ25s using the coil pack above don't need our coil driver. This coil pack can be driven directly out of the SDS ECU. We can supply both 5 and 12V tach signals out of the EM-5 ECU.
The EG33 may use our supplied 6F coil pack or the OE coil on plug setup. The factory Subaru TPS can be used. Systems come with GM air and water temperature sensors or optional Bosch sensors. Our simple Hall effect crank sensor replaces the multiple factory magnetic crank and cam sensors.
Photos below of our twin turbo EG33 in our RV10
Daniel MacPherson's EA81 powered Windfire helicopter, Idaho, USA. EM-5 4F equipped.
The installation has 145 hours of flight time on it as of Dec. 2014
RV7 powered by Subaru EZ30 six cylinder owned by Bengt Bergsten in Sweden. EM-4 6F equipped.
Bjorn Anders Horne flies this EZ30 turbo powered RV7 in Norway. He reports 170 knots true on 9.25 Gal/hr. 370 hours on the setup as of Nov. 2014
Reg Clarke has flown this direct drive EJ25 powered Q2 for many years and 800 hours with SDS. 200 knots TAS at 12,500 feet on 5.5 gal/hr.
Allen Burruss from Stevensville, Montana flies this Glasair FT-S-II powered by an EZ36. 40 hours as of Nov. 2012. 180 mph on 6.5 gph.
Dennis Glaeser flies this RV7A powered by an EZ30 with IVO prop. 150 knots on 9.5 gph.
The photos below show the Crossflow EG33 powered Bushcaddy of the McWilliam brothers in Ontario, Canada. Now fitted with an SDS EM-4 6F and proper Garrett turbocharger. Now fitted with a Marcotte PSRU.
EJ25 turbo RV7 owned by Shane Getson, built by Ralph Inkster, Springbank Airport. EM-4 4F equipped.
A short video of the engine running.
Second flight video
Some more video of high power engine runs, takeoff and overhead passes
Dan Shilling's Bearhawk, N61AK, with EG33, Autoflight gearbox, Ivo Prop, SDS EM-4 6F Located in Anchorage Alaska.
RAM Racing Engines builds Subaru engines for aircraft conversions:
Gordon Wardstrom's Rover V8 powered Bearhawk. SDS equipped. Over 1000 trouble free hours to date. Runs head to head with IO-540 Bearhawks.
From Mike Crene of Kiwi Mustangs in New Zealand: Here are some photos of my Titan P-51 Mustang replica powered by the 2.5 liter Suzuki V-6 engine.
"I am flying the SDS EM4-6F in my Mustang with excellent results and reliability, and having the hand held programmer makes fine tuning ‘a breeze’. I am very pleased with the SDS system and would highly recommend it to anyone for cars, boats and aircraft."
SDS is the OE supplied EMS for Mini Merlin and Honda V6 powered Titan T51s.
The air to air photos below were taken by Kathy Bland.
Suzuki fitted with Autoflight gearbox and large prop
Ben Chester-Master in the UK flies this beautiful Titan T51 replica powered by a V6 Suzuki
Ben is the UK distributor/ go to guy for the Titan T51 replicas.
Chris Gentry of T51 Aero in Florida, flies this 2.7L Suzuki powered Titan T51
Shaun Winson's R80 Tiger Moth replica in Australia. Suzuki G13B powered and SDS EM-4 4F equipped.
Aero Classics 111hp Suzuki 1300cc twin cam powered Tiger Moth replica in New Zealand. EM-4 4F equipped.
The photos below were sent along by Kasper Naef from Nelson BC. His turbo G13 powered highly modified Rans S-7 Courier (stretched fuselage and new wings) used an SDS EM-4 4F system.
Rick Robert's 1.3L Suzuki. EM-4 4F equipped.
Michael Rutherford reports excellent performance from his turbo and SDS equipped G10 running through a Raven redrive. Please note, this system is no longer in production.
Les Smoot's J-3 Kitten powered by 84 cubic inch 4A084 GPU engine fitted with EM-4 4D fuel injection system
Kasper Naef with Honda Fit engine flying with SDS fuel injection. He reported similar performance to the turbo 1300 Suzuki he replaced. About 5 gph at 5200 rpm and 100 mph on amphib floats.
Instrument Design Inc. (Tom Hodgson) is now test flying a Honda Fit engine fitted with an SDS EM-4 4F system after extensive ground testing. Flight time as of April 2014 is 180 hours.
Hall sensor mounting detail on the Fit engine
New intake manifold, July 2014
We also supply Titan Aircraft with systems for the Honda V6 powered T51 replica fighters.
This is Jim Auman's beautiful Honda V6 powered T51 fitted with the 84 inch Whirlwind propeller.
Honda V6 powered Raven owned by Gilbert Belair, Ontario, Canada
We supplied our first system for a Lycoming O-320 back in 1997. One or both mags can be eliminated by using the 4F system. The fuel system must have a provision to return fuel to the selected tank, usually with an Andair Duplex fuel selector valve. Larger injectors are required than those on automotive applications due to the extremely large cylinders on these engines, despite the low specific hp output. We can supply a 60mm throttle body to replace the carb. Tim Collard's O-320 powered Mustang 2 (below)has been flying with an SDS 4D for many years. Joe Block has been flying his SDS 4F equipped Lycoming Glastar (in links below) since June 2003. As of Jan. 2007, he had 470 hours on it.
Peter Krok switched his 7A to Lycoming from Subaru and retained his SDS ECU with Robert Paisley's EFII system.
Tim Collard's O-320 powered Mustang 2. SDS 4D equipped
Injector installation details.
Note fire sleeve/ heat shielding to protect fuel line from infrared radiation due to proximity of exhaust pipes.
08/10/05 update from Tim Collard: "My Mustang 2 has been running on your system now for over 225 hours with no problems [other than my bad wiring]. Getting excellent fuel burns, very even temps, great start up and smooth running. Don't understand why everyone doesn't get a SDS system."
Joe Block's O-320-E2D powered Glastar is fitted with an SDS EM-4F
Joe has 470 hours on the installation so far and reports that he cruises at 30-50F lean of peak and 6.5 GPH at 75%. Operation is very smooth with very close EGTs between cylinders.
Photo showing kit components for Lycoming O-235/O-320/O-360 and Continental O-200 engines (fuel only). ECU, programmer, dual fuel pumps, fuel pressure regulator, fuel block, vacuum plenum, fiitings, fuel filters, throttle body, injectors, lines and bosses. Not shown is wiring harness. You need fuel return lines to the fuel tanks on aircraft having more than one tank and an Andair Duplex fuel selector.
CNC'd parts available for Lycoming 320/360 engines for the DIYer.
Throttle body, magneto and fuel pump block off plates, automotive spark plug adapaters, single and dual crank sensors, crank sensor mount, CHT and IAT sensor adapters, injector bosses (side or top feed fuel connections)
Lycoming direct bolt-on 60mm TB with CNC'd 7075T6 throttle arm for vertical or horizontal sumps. Weight 17 ounces with TPS. 2.5 inch snout adapts to airbox with silicone hose. Also shown in photo is IAT sensor adapter to bolt to airbox.
Coil mount bracket for Lycoming 4 cylinder engines, mounts to rear top of crankcase
Magneto cover in place
Hall sensor mount and dual Hall sensor in place
The injector bosses we supply must be welded in position on your induction tubes in this position and orientation
For Lycoming, Continental, Jabiru and Rotax four cylinder, dual plug engines, we can supply these lighter weight coil packs which save about 1.25 lbs. each over our standard coil packs.
For O-200 engine kits, see above. Along with Mike Dacey's six cylinder Conti, we have done a number of smaller Conti engines, the first back in 1994. Mark Snow was an early SDS user on his C-85 powered Dragonfly, accumulating over 750 hours. Justin Mace currently has 350 hours on his SDS equipped, O-200 powered Dragonfly. See more details on these aircraft below:
Fuel and spark control kit for O-200. Wiring not shown. 15 lbs complete.
Jabiru 2200/3300 Engines
EFI kits for Jabiru 2200 and 3300 engines are now available.
Jabiru 2200 EFI kit with single fuel pump (fuel control only). $3100US. Wiring harnesses and air filter not shown. For twin fuel pumps, add $160. We recommend our wideband AFR setup to properly tune the system $135 (displays air/fuel ratio in SDS programmer).
Jabiru 3300 EFI kit with single fuel pump (fuel control only). $3600US. Wiring harnesses and air filter not shown. For twin fuel pumps, add $160. We recommend our wideband AFR setup to properly tune the system $135 (displays air/fuel ratio in SDS programmer).
Rendering showing CNC'd and anodized shaftless 45mm throttle body and adapter for Jabiru engines
Hall sensor mount for Jabiru engines
Injector installation on 3300 by Michael Crowder
Update Aug. 27/10
From John Milsteed in Australia who recently installed SDS fuel injection on a Jabiru 3300 engine: "The system is still working well, picked up around 8-10 kts indicated due to the rpm increase and fuel usage went from 26 Lts/hr. to around 18 Liters/hr.- not bad".
Some photos of John's installation below:
John is using the carb as a fuel backup and reports that works quite seamlessly.
Throttle body replaces Bing carb
Thomas Hauklien in Norway sent these photos of his customer's Jabiru 2200 powered Sonex fitted with SDS EFI. He reports 250 more rpm over the carb and the engine will idle down to 200 rpm!
Thomas is working on this new turbo Jabiru in a Sonex. Very nice!
Thomas Hauklien from Edge Performance in Norway sent us this photo of this Verner powered Muphy Renegade fitted with SDS.
Thomas Hauklien from Edge Performance in Norway sent us this photo of his turbocharged VW engined Sonex with SDS fitted:
See the engine running here: http://www.youtube.com/watch?v=SYEaTwKQcv0
Here is another nice video Thomas put together showing the whole installation: http://www.youtube.com/watch?v=UnkeUdwEF-w
Waiex 2180 VW with SDS EM4 built by Peter van Schalkwyk, Raleigh, NC. First flew May 2010 Approaching 400 hours as of May 2014.
Single plug EM-5 4F kit for VW engines
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
Available with top feed or dual side feed tops
60mm generic throttle body available for engines up to 200hp.
High flow, Billet, annodized, CNC'd shaftless 55 and 45mm throttle bodies for Rotax and Jabiru engines
O-ring sealed base
We stock top quality Aeroquip and Earls fittings, filters and hoses now
Genuine Walbro pumps, made in USA
Quality Borla AN6 fuel pressure regulator, made in USA
New 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
Same block as above but with 1/4 NPT inlet and outlets for externally mounted regulator
The Gold Standard
Racetech dual pump module. 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, integrated sintered bronze filter which is easily inspected, cleaned and replaced. 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 $625US with pumps for up to 300hp. $680US with pumps for up to 400hp. Approx weight as shown- 3 lbs./ 1370 grams. Supplied with 4 1/4NPT plugs. No dealer discounts on these items.
Module shown with optional fuel pressure regulator mounted to avoid mounting the regulator firewall forward.
Regulator and mount kit $255
Note we use only genuine, made in USA Walbro pumps, genuine made in USA Borla regulators and US made filters and AN hardware- no cheap Chinese copies/ ripoffs. Body designed, machined and anodized in Canada. We support jobs and industry in North America as much as possible.
We can supply many individual components and kits for EFI/ EI conversions. We believe each installation is custom and will tailor systems to your individual needs. Because of the variations in airframes and parts/ installation preferences we don't publish all kit prices here. It's better to contact us via email to work out what you want and need for your particular installation. We can quote you from there. E-mail:firstname.lastname@example.org
Aircraft/ Engine Forums
For a lead scavenger replacement for use in non certified applications from Decalin Chemicals.
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SDS products are manufactured, supported and sold by:
Racetech Inc. E-mail:email@example.com
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#5-304 Noorduyn Park
Calgary, Alberta, Canada
Phone 403-671-4015, Fax 403-453-7687
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