5. Engine mounting system
- Custom engine mount – Depending on the aircraft application, the engine mounting configuration is setup on our custom adjustable firewall welding jig. Our engine mounts are constructed using chro-moly steel. The tubes are cut and fitted exactly to the mounting specifications and are stress relieved for optimum strength. The mounts are designed to transmit the least amount of vibration possible into your aircraft. The mounts are then spray painted using high quality, durable enamel paint
- Engine cradle – The engine cradle is fabricated by CNC machining the mount seat adapter and cutting and fitting chro-moly steel tubes. The entire cradle is then secured to a customized welding jig and welded together. The cradle is then spray painted using high quality, durable enamel paint.
6. Engine assembly
Once all of the engine parts have been fabricated and assembled, they are transported to the engine assembly room. This large, well-lit, highly clean, sound barriered room is critical to the assembly process. This process should be done with as much facility and concentration allowable. We've gone to great lengths to create a room were distractions and dirt are minimized, allowing our engine assemblers to concentrate fully on assembling a perfectly built product.
7. Propeller speed reduction unit fabrication and assembly
The Crossflow PSRU is an internal spur gear reduction drive of proprietary design that had undergone 3 years of research and development. It has been specifically designed to work with Subaru automotive engines converted for aircraft use by our engineers. The PSRU employs some unique features that we believe make it the best choice on the market for Subaru based aircraft engines. The PSRU is assembled from a variety of components that have been designed and fabricated in house using our CNC mill and CNC lathe. All the parts used in the PSRU assembly are listed:
- Bell housing
- Gear housing
- Pinion gear housing
- Pinion gear cover
- Propeller cover
- Center plate
- Flywheel
- Large pinion gear
- Small pinion gear
- Large gear
- Governor cover
- Vacuum pump cover
- Bottom cover
- Finishing / detailing / painting
- Assembly
8. Engine final assembly and performance testing
During this final stage, the PSRU and starter are installed. The completed engine then transported to the dynamometer lab and mounted for testing. During testing, the Crossflow dynamometer automatically records true horse power, torque, RPM, elapsed time, etc. at over 200 readings per second (that's per channel, not just a total). It can is also set to automatically apply Standard SAE correction factors for air temperature, barometric pressure, and relative humidity. A thorough engine analysis is performed and real time trace graph displays are studied. Publication quality color graphs and detailed reports are generated. Once the engine has met our stringent performance requirements it is approved for shipping and transported to the docking bay.
a. Accompanying documentation - Each Crossflow Engine Solution package is accompanied by a comprehensive data package that provides traceability on the components, a build record and a test record. This is also accompanied by a series of unique photographs associated with the engine and installation package Serial Number. Included is a Build Completion and Acceptance Test Certificate that identifies the corrected brake horsepower, torque and fuel consumption of the engine and the Crossflow staff who assembled and tested the engine and the installation package. In addition, a comprehensive installation and maintenance manual accompanies each installation package.
b. Shipping and Customs documents - Crossflow will prepare and provide all shipping and customs documents that are required to accompany all of our products.
c. Preparation for Delivery - Each Crossflow product is carefully prepared for delivery. Open pipes are properly capped. Electrical Connectors sealed and wires are restrained. Liquids are drained and the appropriate preservation process invoked.
d. Packaging - The packaging employed is dependent on the mode of transportation. The engine and installation is wrapped in a plastic shroud and placed in a foam ‘nest' located in a rugged wooden crate.
e. Delivery - The method of delivery is determined by Customer instruction. The packaging employed is designed to protect the engine and installation package from damage when any mode of transportation is used. Road, rail, air or sea or a combination of these.
Regarding pricing
Our list price for the Crossflow CF4-20T Engine Solution is US$28,105.00.
A 35% payment (US$9,836.75) will be required initially to commence the production of your engine.
A second 35% payment (US$9,836.75) will be required 2 weeks after the date of your first payment
The sum of US$8,431.50 will be required after the completion of your engine and prior to the shipping of it to your location.
We also recommend that you provide us with travel expenses and professional accommodations for a 3 day stay for one of our technicians at your location to assist you in the installation of your engine onto your firewall. During this time we will also provide you with some training about the operation of your Crossflow engine as well as doing performance testing to ensure that everything is working properly.
Regarding lead times
A total lead time of 2 months from the date of your first payment will be required to produce your engine
The first week of production includes the delivery of your engine core from Japan. We strip the engine down completely, removing every single part from the original engine. We’ve intentionally chosen to begin with used engines particularly from Japan for several reasons. Firstly, Japanese environmental law requires that every automotive engine be rebuilt after 50,000 kilometers. This is an ideal situation for the Crossflow engine because after this relatively short engine operation time the Subaru aluminum long block has been conditioned by heat during use. This ensures that the block has no cracks or flaws in the casting. This mature engine block now becomes the core of the Crossflow power plant. Every other component used in a Crossflow engine except the cylinder heads, crankshafts, connecting rods and valve covers is custom fabricated here at our facility and/or ordered new directly from Subaru. During this time we deglaze the cylinders and recondition the cylinder heads. We then fabricate our own intake and exhaust systems. The exhaust system is then ceramic coated for longevity against the natural elements.
During the second and third stage of production we fabricate the electrical wiring harness, the Crossflow Propeller Speed Reduction System (PSRU) and the engine mount particular to your aircraft. We then carefully assemble the complete engine package in a climate controlled clean room. After the assembly is complete the engine enters our internal Q&A process and dynamometer testing. After the engine has met our operation standards it is crated and prepared for delivery.
Crossflow CF4-20T Engine Solution