MOTORES BILSAM

After 2 years of experiments we have developed reasonably priced four stroke power plants for light aviation. More than 12 years of experience in converting the auto engines for racing in Poland, we have gained great knowledge of engines and with young team of engineers 2 years ago we decided to provide aviation community alternative auto engines for aviation use.
We chose Suzuki engines because of their compatibility, light weight, all aluminum construction. These engines are produced in today's cars and are available in any quantity. By choosing current production engines we have eliminated the worry of our customer about spare parts, if some things goes wrong with our company, you can buy all over the world spar parts for these engines. So we really do not need to establish web of our distributors all over the world to provide service, any authorized auto-shop in the world can handle this.

RELIABILITY AND EFFICIENCY
Auto industry have billions of dollars of funds for research and development purpose and then they have very tough competition with each other. So we believe that these engines are far more superior in quality, performance and in technology than aircraft piston engines. Then they are very fuel efficient thanks to water cooling and auto fuel is 1/2 the price of Avgas.

MODERN TECHNOLOGY
All new modern engines are water cooled having following benefits over air cooled engines
okwater cooled engines add few more components but:
- They burn about 12 to 15 %less fuel than air cooled engine ,which means your endurance will be more with water cooled engine or less mtow.
Pls note that MR.RUTAN ordered specially for his around the world flight water cooled engine from continental. Without that modification that flight with out refueling was not possible. He would have been simply run out of the fuel.
- Water cooled engine works at constant temperatures maintained by thermostats, regardless of altitudes, power settings and air temperatures.
- Controlled temperatures means tight internal clearance of the components, adding more efficiency and reliability of the parts.
- Cabin heat can be provided with out the risk of carbon monoxide poising. Which is associated with air cooled engines where the heat is drived from the hot burning gases.

INNOVATIVE FEATURES
- Customized fuel injection system to compensate for the temperature and atmospheric pressure differences at different flying altitudes
- Integral toothed Gear Reduction Drive with anti tensional resonance device to counter the shock loads to the propeller
- Customized lightened fly wheel
- 1000 hrs TBO
- Any reduction ration available
- Flat positioned engine to fit almost all the engine cowls containing Rotax or Jabiru, or HKS engines
- Very reasonable priced
- Spar parts available all over the world

Diffusion
After great increasing demand of our power plants. To meet the production dates and delivery schedules Bilsamaviation has joined hand with legendary polish auto engine converter for racing and producer of sports cam shaft producer magistrate engineer. Mr. Lech Swiatek and his team. this diffusion will enable us to increase our production volume and at the same time Mr. Swiatek has taken the responsibility to make further improvements. Here are the details:

1) all customers will get turn key engines, which means all the wiring and all the harness are preinstalled with all the engine instrument's sensors and senders
2) carbon fiber exhaust
3) carbon fiber manifold
4) carbon fiber oil sump
5) new light weight and better reduction unit
6) increased hp for L-S 1300(now 120hp)
7) more better and favorable torque curves ,thanks to new designed cam shaft
8) increased hp for the L-S 1300 now 100 hp and 120 hp versions at lower RPM's with help of new cam shaft and other modifications
9) guaranteed deliveries of up till 15 to 20 engines per month
10) complete fire wall forward packages with engines mounts for following aircrafts from january 2004

a) sky ranger
b) cosmos trike
c) air creation trikes
d) zodiac ch701
e) zodiac ch601
f) air trophy stool 2000
and of course al bilsam flying machines

L-S AERO ENGINES TECHNICAL INFORMATIONS

ENGINE MODEL	L-S 1000	L-S 1300	L-S 1300XP
Cylinders	In line 3 cylinders OHC	In line 4 cylinders, OHC	In line 4 cylinders, OHC
Cooling	Water cooled	Water cooled	Water cooled
Displacement	1000 CC (61 cm³ )	1300 CC (80 cm³ )	1300 CC (80 cm³ )
Power output	80HP @ 5900RPM	100HP @ 6000RPM	120HP @ 6000RPM
Maximum torque	100.9NM @ 4722RPM	130NM @ 4800RPM	135NM @ 4800RPM
Bore	73,9 mm	73,9 mm	73,9 mm
Stroke	76,9 mm	76,9 mm	76,9 mm
* All up weight	78,6 kg	72,5 kg	89,7 kg
Reduction ratio	2,40:1	2,40:1	2,40:1
Ignition	Electronic Ignition	Electronic Ignition	Electronic Ignition
Alternator	30 Amp	30 Amp	30 Amp
* Full consumption	10 liters @ 75% power at 1500 meters altitude	12 liters @ 75% power at 1500 meters altitude	12 liters @ 75% power at 1500 meters altitude
Fuel system	Multi port fuel injection	Multi port fuel injection	Multi port fuel injection
Compression ratio	10:8	10:8	10:8
Firing order	1,2,3	1,2,3,4	1,2,3,4
Advance angle	10° BTDC	10° BTDC	10° BTDC
Electrode gap	0,8 - 0,9 mm	0,8 - 0,9 mm	0,8 - 0,9 mm
Trans mission	Toothed gear	Toothed gear	Toothed gear
Trans mission type	Helical type gear with dynamic vibration damper	Helical type gear with dynamic vibration damper	Helical type gear with dynamic vibration damper
Transmission oil / gear box	SAE 85W90-API-GL4 (mineral oil)	SAE 85W90-API-GL4 (mineral oil)	SAE 85W90-API-GL4 (mineral oil)
Transmission oil quantity	0,35 liters	0,35 liters	0,35 liters
Lubrication system	Wet sump (oil pump)	Wet sump (oil pump)	Wet sump (oil pump)
Lubrication oil type	SAE 10 W 50 - API-SH 3,8 liters ( semi synthetic)	SAE 10 W 50 - API-SH 4,00 liters ( semi synthetic)	SAE 10 W 50 - API-SH 4,00 liters ( semi synthetic)
Cooling capacity	4,5 liters	4,5 liters	4,5 liters
Fuel	Minimum 98 octane	Minimum 98 octane	Minimum 98 octane

ROUTINE MAINTENANCE FOR L-S 1000 AND L-S 1300

COMPONENTS	CHECK	RENEWAL
Oil level	Before every flight	Every 100 hrs or, one year period
Coolant level	Before every flight	Every 100 hrs or, one year period
Oil leakage	Every 150 hrs	150 hrs
Oil filter	-	Every 150 hrs
Spark plugs	-	Every 150 hrs
* Air Filter	-	Every 150 hrs
Fuel filter	-	Every 150 hrs
** Transmission gear box oil	150 h
*** Dynamic vibration damper torque	150 h

* Not renew but clean oil by using JR clean and change except oil leak
** Transmission do not require oil level checking, or renewal except oil leak
*** Vibration damper must be checked for elastic resistance by pulling propeller by hand with NO Running ENGINE

REMANUFACTURING PROCEDURE

PARTS		CONDITION
Gaskets		New
Timing belt tensioner		New
Spark plugs		New
Timing belt		New
Piston rings		New
High tension cable		New
Starter		New
Pistons		New
Big end Biering		Reconditioned
Water pump		Reconditioned
Inlet value		Reconditioned
Exhaust value		Reconditioned
Distributor cap		Reconditioned
Oil pressure indicator		Reconditioned
Alternator		Reconditioned
Cam shaft		Custom modified

TUNING PROCEDURES FOR L-S 1000 AND L-S 1300 AERO ENGINES

Cylinder head verification		(i) Inlet and exhaust channels (ii) Combustion chamber (iii) Compression ratio
Cam shaft		Sports cam shaft
Inlet manifold		One throttle sport inlet manifold
Exhaust		3 in 1 sports carbon fiber exhaust manifold
Fuel and ignition system		Multi port injection with electronic ignition

REDUCTION UNIT
Specially hardened helical type toothed gear unit 25mm thick toothed wheels helical type gear boxes are the best solution for low vibration and less noises which add the components reliability and longer life we in cooperate special rubber cushioned between the wheels to further improve the anti torsional effects of whole system.

LS 1000 engine
The owners manual

1.General dimensions.

2.Details.
Origin of engine.
The base is Suzuki Swift G10 car engine.

Construction.
LS 1000 engine is predestined for ultralight aviation. Mega quality and reliability of engine parts is guaranteed by origin from car industry. Engine block and cylinder head are made of light alloy and this gives little weight. Angle of inclination of engine is 20 degrees from level to close general dimensions to boxer engines and secure little dimension between axis of propeller and top line of engine.
Inlet manifold and oil sump are completely original constructions. They are made of vinyl resins and strengthen by carbon fiber LS 1000 engine is feeded by electronic fuel injection with electronic controller unit.

Reduction gear .
The helicoial gear with grinded teeth secure high reliability and silent-running. It is equipped with dynamic anti vibration damper and separate oiled.

3.Safety rules.
It is not allowed:
starting the engine without checking every flight operation and when routine maintenance are not compete
starting the engine without propeller
starting the engine when any controller is not working
leaving the engine working
crossing maximum RPM
using the engine to acrobatics
starting flight when the engine is not working correctly
opening cooling system when the engine is hot

Necessary is:
do routine maintenance according with the instruction
use recommended spare parts only
use recommended fluids
secure engine and components for storage

4.Engine systems
Cooling system.
LS 1000 is water cooled engine. The cooling system is pressured pump-assisted thermo-sypfon type.
The system consist of the radiator, water pump, thermostat and expansion tank. Thermostat starts to open at the water temperature between 82-88 ° C.
TEMPERATURE RANGE =90-100°C

Diagram

Fuel system.
Fuel is inducted from fuel tank through the filter to the injectors. The fuel pressure controller keeps up fuel pressure between 2,5-3,5 Mpa. Fuel charge is controlled by computer.
Warning:
- fuel pump must be mounted under fuel level
- fuel pump must be fuel filled
- running the pump without fuel longer than 5 SEC . can cause serious failure

Reduction gear.
The helicoial gear with grinded teeth. Housing is made from light alloy.
The reduction gear is equipped with a dynamic anti vibration damper. It is oil filled through the top gate (0,2-0,25 ltr.) There is no bottom outlet and level gauge.

Oil system.
The oil system is pressured type with oil pump driven from crankshaft with full flow oil filter.
The oil pressure indicator is checking oil pressure. Running engine without minimum oil pressure can cause serious failure. The minimum oil pressure is 0,1 MPa about 2000 RPM (oil temperature 90 ° C.

TEMPERATURE RANGES
90-110degree centigrad

5.Exploitation and service.
Starting.
Before start the engine every flight action and safety rules must be checked.
When the engine is cold or air temperature is below 20 ° C switch position "1" on the computer.
After 5 sec. after starting the engine switch position "0". When the engine is hot or air temperature is above 20 ° C switch position "0" on the computer.

ROTARY REVOLUTION

Bilsamaviation has observing the development of rotary power plants in united states for last 8 years and has decided to pursue this idea further and develop the most reliable power plant for light aviation

This seems to be a deviation from general trend in Europe where high fuel prices have motivated few companies to develop diesel power plants for the light aviation but according to our logic the diesel engine will always be heavier and average ultralight pilot fly about 40-50 hours per year

So really there is very less fuel saving costs, and this can be compensated by the longer TBO (2500hours and planned to be increased to 3000 hours in near future)

And fixed general over haul cost of only 1999 euro for our rotary power plants

History

Dr. Felix Wankel invented the engine in 1930 .after 20 years of development and improvements the first prototype was built in 1950

But it was odd looking engine (too futuristic for it’s time)

And did not created any commercial success

But one company saw the superior kinematics of this concept and bought the rights of the engine

This was japanese company named Toyo Kogyo or known as Mazda motors to the world

Mazda created state of art computerized test facility to further improve the concept and invested millions of dollars and thousand of hours on rotary concept

After 17 years of long research and development Mazda started selling cars with rotary engines in 1967

Over the years several engineering challenges were encountered and lot of lessons were learned from every day use of this engine.

More than 2 millions cars were sold with this engine in very short period (it took Lycoming and Continental more than 40 years to sell about 400000 aircraft engines)

In 2003 Mazda introduced new sports car RX 8 with 4^th generation Renesis rotary engine

This engine is the by product of 37 years of experience in rotary technology and Bilsamaviation has fully confidence to the concept. Let’s see why the rotary is perfect choice for aviation.

In aviation the most important factor should be safety not fuel costs (diesel concept)

rotary verses piston engine

Piston engines

In piston engines reciprocating action produces tremendous stress on the engine parts like connecting rods, pistons, pins, valves, valve springs, camshafts, lifters push rods, etc

In piston engine parts move, then stop, then up and down and in all directions twice per revolution

So it’s impossible to perfectly balance the piston engine

As the parts reciprocate, and oscillate, and they through off their center of gravity and normal piston engine has about 44 moving parts ,so you can imagine what mess is inside when engine is working let’s analyze the motion of typical piston engine, rotating at 5000RPM (cruise RPM of Rotax 912 at 75%power)

The bore is 4 inches

Stroke is 3 inches

At 3, o clock position of the crank, the piston is moving down the bore at maximum speed

At 9.0 clock position of the crank, piston is moving up the bore at maximum speed

At 12.o clock and 6, o clock position its stopped at the top and bottom of the bore

Now stay with me

The circumference of the crank is pi x 5inches

Which is 15.7 inches or 1.31feet

We have cruise RPM of 5000

5000RPM = 84 rps (rev.per second)

Crank pin is moving at

84 x 1.31 =110 feet/second moving in a circle

Piston speed is same as pin speed at 3, o clock and 9, o clock position.

Which means it takes crank1/84 second or 0.0119 seconds to rotate once

Now the rotation of the crank from 12,o clock to 3,o clock will take one quarter(1/4) of 0.0119 seconds that is 0.0029 seconds

There fore piston accelerated from dead stop to 84 feet per second in only .0.0029 seconds so average acceleration of crank would be,

Crank acceleration=speed of crank insec. /time in seconds=84/0.0029=28965 feet per second

This is tremendously fast and here is the night mare

We know (i hope)

1g=32 feet/sec. so 28965 feet per second / 32feet per second = 905g,s

Now lets assume that connecting rod, piston pin and piston with rings weighs about 7 lbs and piston about 3 lbs.

So the inertial load of 3 pound piston to the connecting rod=3x905=2715lbs=(1123kgs)

So poor connecting rod is pushing 2715 lbs of piston in every0.0119 second

Then 7 lbs of collected load of connecting rod, piston pin, piston with rings is exerting inertial load on the crankshaft=7x905 =6335lbs =(2879kgs)

So it’s only the miracle of metallurgy science and almost 100 years of work and billions of dollars spent by auto industry that the piston engine last so longer

But aviation is high risk business/hobby

And we can see the piston engines are very prone to damage and any small minor maintenance problem/negligence can lead to engine failure

They last longer in the cars as they are working at about 30% of the power but in aviation we need 65%to 75% the power

That's why Lycoming and Continental have stayed to large displacement low RPM engines (high RPM means, very high inertial loads on the parts) but they are left behind as they have not modernized their engines with fuel injections, water cooling and other high tech goodies

Rotary engine

Rotary engines are not reciprocating engines, every parts move in a circle or in same direction

There are only 3 moving parts, not 44 to 46 as compared to piston engines

There are no exhaust valves to melt or burn (in piston engine 80% of the engine failures are caused due to exhaust valves problems)

These poor valves run at extremely hot temperature's and opening and closing about 1200-1500 times per minute

Their is no cam shaft to worry about in rotary as there isn't any Rotaries are perfectly balanced just like turbine or electric motors

In rotary propeller gets 6 power impulses per revolution which means it will take piston engine to have 12 cylinders to have same smoothness as twin rotor, rotary engine

Best thing is rotary never fails like pistons engine

You may lose partial power if you loose your coolant and you will still have some power to get to the nearest landing place

misconcepts about rotaries engines

1. 2 stroke engine

Lot of people think its 2 stroke engine which is not truth

It has four cycle like

1) intake

2) compression

3) expansion

4) exhaust

And it fires twice per output shaft revolution

2. High fuel consumption

That was true for the early models but new RX 8 engine has fuel burn very close to today's modern piston engines as RX 8 has now side exhaust ports and any residual un burned fuel is recirculated to next combustion cycle. The exhaust port timing has been modified and RX 8 has lower exhaust temperatures confirming the low fuel consumption

3. High oil use

The main reason for the high oil use in the early models was the quick wear of the rotar seals, this problem has been fixed by new ceramic silicon carbide seals and they are 700% stronger than metal seals

4. Complicated engine

This reason is really very astonishing as really their are no complication in construction,

lot of people do not under stand the engine and they stamped it complicated engine

then why sky is not full with rotary engine powered aircraft's?

Good question or why Mazda does not certify this engine for aviation use

The main reason is commercial

As aviation is such small market for Mazda and second they will never allow any aviation authority to dictate them what to do or not as when you certify the engine you have to go for very long and tiring procedure of approvals for any small modifications and i think Mazda do not want to have this headache, so here comes Bilsamaviation in the picture

Engine itself is not a problem

To convert the engine for aviation use following engineering challenges have to be solved

Custom made oil pan
Custom made exhaust system
Custom engine mount
Custom cooling ducting and plumbing
Proper cowl design to prevent back pressure lock on the radiator so you do not get the heating problems
Modified water pumps inlets and out lets
Modified intake manifold
And most important, reliable gear reduction unit

Bilsamaviation has taken up these challenges and developed the perfect light and reliable engine for aviation use

Advantages

1. compact

2. high power to weight ratio

3. 2500 hours TBO as compared to 1200 to other piston engines

4. very low fixed over haul cost of about 19999 euros

5. reliability

6. simple

7. smooth like electric motor

8. high damage tolerance

9. low purchase cost

10. spare parts backed by one of the world's biggest company (Mazda motors)

11. low cost auto fuel operation

Performance specifications

Engine type

Rx8-SR

Rx8-XP

Rx8-TR

All up dry weight

68,9 kg

120 kg

Horse power

100 hp

120 hp

240 hp

Maximum RPM

7500

8000

7500

Cooling

Water & oil cooling

Water & oil

cooling

Displacement

650 cc

1300 cc

Maximum torque

125 nm @

4500 RPM

140 nm @

4500 RPM

“

Reduction ratio

3:1

Alternator

24 amp

30 amp

Fuel consumption

15 liters

18 liters

25 liters

Fuel system

Multi part fuel injection

Multi part fuel injection

Multi part fuel injection

Compression ratio

10:1

Transmission type

Helical type gear with dynamic vibration damper

Transmission oil

Sae 85 w

90-api-gl4

Sae 85 w

90 api-gl4

Sae 85 w

90 api-gl4

Lubrication system

Wet sump

Oil pump

Wet sump

Oil pump

Wet sump

Oil pump

Fuel

95 or higher octane

95 or higher octane

TBO

2500 hours