Updated Sonex Installation Kits for Rotax 912 Series Engines.
A new development to support Sonex Aircraft's new Rotax engine mounts.
Sonex has felt the pressure from the aviation community for Rotax engine installations for many years.
In response, Sonex released their bed mount that would exclusively handle the 912 series of engines some years ago. While this engine mount underwent some changes over the years, Sonex recently released their new engine mounts for all aircraft they produce that have a propeller. This will encompass the Onex, Sonex, Waiex, Xenos, Highwing, both Legacy and B models. These new engine mounts, in new Sonex fashion, are white and will handle Rotax 912UL, 912ULS, 912iS, 914UL, 915iS and 916iS. Quite a leap and a bold new move for the company that has largely been powered by Aeroconversion's Aerovee and Aerovee Turbo (Sonex's very own power plant) and Jabiru's 2200 and 3300 engines since the very beginning.
The possibilities at this point are truly endless when going Rotax. With engine options ranging from 80-160hp, max service ceiling of 23,000 feet (though proven by Cub Crafters you can achieve 36,000 feet), 2-6 blade propeller configurations, all engines have a 2,000 hour TBO (except the 915iS at 1,200 hours), and fully broken in when delivered with warranty, from $18,000-$62,000. An overhauled Lycoming of similar power, more weight, and naturally aspirated, costs as much as Rotax's 916iS. A new Lycoming? Take a guess.. The choice is easy IF there's support options.
In recent months we have been developing a new installation kit for the 912 series engines that will work across the board with Sonex, Waiex, Xenos, and Onex. No matter Legacy or B model, conventional or tri-gear. While intended for the Sonex line of aircraft, this would also work for basically any aircraft utilizing a Rotax 912 series engine and suspension mount.
While not available (yet), we will be working on an installation kit variant for the turbo charged Rotax engines in the near future.
Featured above is Sonex employee Cris Nash's Sonex B with the 915iS in position to check fitment for future installation on the Sonex Highwing.
In our kit we're using genuine Rotax cooling parts, Toucan dual exhaust system (not included, but available), fiberglass components, weldments, bracketing, hoses, fittings, and other miscellaneous components. *Fuel system parts and wiring not included.
We designed and installed our new installation kit in a Sonex Onex. An engine installation package that doesn't have much real estate. We figured if it functioned in this airframe properly, it would be an easy and much roomier installation in other applications.
We have performed extensive ground testing by comparing warm up times, full power tethered pulls, and overall temperatures in 100 degree environments against other aircraft as well as our Rotax powered Sonex as the "control" aircraft. We have been very pleased with the results.
Recently we took to the skies and tested the Onex and its installation. While we expected it to perform well, frankly, we didn't expect to perform as well as it did. The flight went flawlessly. The plane is so well balanced, it would fly with or without a pilot (although we know that's not possible). It did not have a heavy wing, cooling issues, or any issues to speak of. Very uneventful which is what you strive for on a test flight.
Outside air temperature was 80 degrees Fahrenheit on the ground (2,120msl) and 30.17Hg. Climb rate of 1,300-1,400fpm sustained at 100mph. At 5,300 rpm our temperatures plateaued at 206 degrees Fahrenheit cylinder head temperature and 196 degrees Fahrenheit oil temperature. In terms of speed at 4,000msl the Onex indicates 165mph, and 180mph true. At max continuous of 5,500rpm, we indicated 170-175mph and 190-195mph true and showed temperatures of 210 degrees Fahrenheit cylinder head temperature and 210 degrees Fahrenheit oil temperature. Also no notable temperature increase in a slow speed, steep sustained climb to agitate the engine. While still subject to propeller pitch changes and diameter changes, these were impressive initial numbers. It also helped that this Onex is flush riveted to increase performance. In stall testing the Onex stalled clean at 40mph, and 37mph with flaps. You are also able to change your wing length by cutting down the wingtips. This will change things quite a bit in terms of climb and cruise depending on which route you decide to go.
While it has flown since, there has been no changes, issues, or hiccups it its performance and will continue its flight testing by its owner.
We're extremely pleased with the installation and we are officially offering the installation to the public.
There's many variables when installing a Rotax in an airframe and we can assist in supplying the components to make it a no brainer. Propeller, spinner, exhaust, engine mount, installation kit, we have it mapped out. Our install kit is being sold for $2,700 USD less shipping. Kits have been shipping out so if you would like to secure your position in line, please fill out our contact form with your aircraft model, items requested from the above , and we can assist you with a total cost and lead time.
It has been a long time coming and we are excited to grow the Sonex and Rotax union. We have more developments coming soon and we're excited to share them with the community.
Visit our Facebook page or Instagram for updates as things progress.
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