Zonsen Aero Engines - Rapture Aviation (Adelaide)

[Rapture]

5 hours ago, BurnieM said:

Have you looked at the oil cooler and its airflow ?

In summer coolant temp is a problem on the ground but oil temp is more of an issue in the air.

Yes, the oil cooler is enhanced also and we will work out the required airflow.

[Rapture]

5 hours ago, Thruster88 said:

Given the problems people have with RAAus registration of jabiru aircraft fitted with Rotax engines how are you doing the engineering approval?  Will you be selling an engine complete with MARUP or an STC as a package? 

This one is 19 registered so is ok. For S-LSA Jab 160Cs, we will develop a MARAP package to be submitted on an individual basis for approval to allow these aircraft to be fitted with the Zonsen engine and continue to be used in commercial operations. We will do the engineering analysis for a standard FWF conversion that we will offer the package for. This is all dependent on folks actually wanting this conversion. We will determine that demand once we have an aircraft that we can demonstrate. If no one wants it, then we won’t go to the hassle or expense of developing the full MARAP package.

[Rapture]

The next instalment in the CA510 110hp installation into a J160 is a bit overdue but here it is.

 

The engine will require a 3” prop extension to fit nicely into the cowling. We are waiting for the extension to arrive from overseas. Once it does, the engine location will be confirmed and the mount will be final welded. 
 

In the meantime, the exhaust system has been welded up and looks very nice. The photo below shows the exhaust system mounted to the Rotax we have been using for mocking things up to keep the new Zonsen engine pristine until the final installation is ready.

 

 

Hopefully the prop extension will arrive soon (it has been shipped so we are waiting for it to arrive) so that we can finalise the engine mount.

 

Bolly is doing a special prop for us which we are excited to trial with this airframe/engine combination.

 

The fuselage work is essentially completed but awaiting painting.  The wings have been painted and are ready to go back on the fuselage.  Once the engine and accessories are mounted, we will have throttle cabling and instrument wiring to do and then we are pretty well done with the installation.

[facthunter]

You need an effective Heatshield between the exhaust and the Oil filter.  Nev

[440032]

Though just a mockup engine, I'd almost bet that filter could not be removed with the pipe where it is!

[T510]

33 minutes ago, 440032 said:

Though just a mockup engine, I'd almost bet that filter could not be removed with the pipe where it is!

Well spotted, will make servicing a lot more time consuming

[facthunter]

My listing for the Filter is Ryco Z 418. You can get an ST (Finer microns).  Nev

[Blueadventures]

1 hour ago, 440032 said:

Though just a mockup engine, I'd almost bet that filter could not be removed with the pipe where it is!

It would be a mockup, my Rotax set up is similar re header to oil filter (although a bit more clearance)  I cannot remove my oil filter whilst the header is in place.  This is not an issue; as I replace the oil filter every second oil change (100 hrs) and remove the header as I 'Kopper kote' the ball sockets of the header to the muffler every 100 hrs.  

 

I see the mock up is tube in tube fit header to muffler and expect it would be a ball / socket type to allow slight movement for alignment etc.

 

 

[onetrack]

I think the photo angle is a bit deceiving, and that filter will come off easily. The filter only has to move out less than 20mm, and it's then totally unscrewed, and can be angled in any direction.

 

Z418 is the same filter the 3.0L diesel Hilux uses. On my Hilux, there's plenty of other crap in the way when taking the filter off, but it comes off easily due to being able to be angled quickly, once undone.

 

I'm in agreement with Nev, a heat shield would be a necessary improvement. One can be fabricated that clamps around the pipe and which follows the pipe contours.

 

Edited Friday at 12:04 AM by onetrack

[BurnieM]

Looks to me like the pipe is too close, more like a 12mm gap.

I agree that keeping the heat away from the filter is a very good idea.

A heat shield may work but would further reduce the gap.

At this stage of the setup angling the pipe outwards makes more sense.

 

Edited Friday at 12:59 AM by BurnieM

[Thruster88]

Have never seen a heat shield for the oil filter on any 912,915 that i have serviced. They all have similar exhaust manifolds.

[Blueadventures]

9 minutes ago, Thruster88 said:

Have never seen a heat shield for the oil filter on any 912,915 that i have serviced. They all have similar exhaust manifolds.

Agree, also about 9 years ago rotax altered the spec of their oil filters to be a couple of mm longer and then they would not come off with the header in place on the factory exhaust system (talking UL and ULS).    

[facthunter]

What other vehicle has the filter so close to the exhaust pipe?. It's risk to heat it.  Even exhausts near steel sumps cause carbon build up like in a stove and it  flakes off causing blockages or fouling anti drain valves.  Nev

[Thruster88]

Also see very little carbon when examining the cut open oil filter paper on Rotax 912,915 engines. I think they have them very well sorted. No carbon stuck to the filter can. 

[onetrack]

I'd have to opine that modern oils do a far better job of lubing and protecting surfaces than they did even 30 years ago.

There has been a lot of R&D into new additives, and a lot of new chemical compounds found in the last 30 years, that are added to current oils - which all make the oil perform better, cope with higher heat levels, and cope with higher levels of contamination and by-products from combustion, than older oils could.

[facthunter]

It's STILL BAD Practice. Very hot oil is not a good idea. Insides of Cowls get Burned by being near exhausts and turbochargers. You Lag fuel and oil lines.  Point Blast tubes at HOT bits Alternators etc. 

[Moneybox]

7 hours ago, facthunter said:

It's STILL BAD Practice. Very hot oil is not a good idea. Insides of Cowls get Burned by being near exhausts and turbochargers. You Lag fuel and oil lines.  Point Blast tubes at HOT bits Alternators etc. 

I've lagged my exhaust manifolds and muffler mainly to protect the many hoses. Since I had to rebuild No.2 pipe it has a slight dogleg too so that the filter can be removed. Neither of these is an allowable modification but necessary in my opinion.

Edited Friday at 01:53 PM by Moneybox

[skippydiesel]

6 hours ago, Moneybox said:

I've lagged my exhaust manifolds and muffler mainly to protect the many hoses. Since I had to rebuild No.2 pipe it has a slight dogleg too so that the filter can be removed. Neither of these is an allowable modification but necessary in my opinion.

Be careful Moneybox.

 

For the most part, Rotax do not endorse "lagging" of the exhaust system. Targeted shielding seems to be more acceptable.

 

I do a bit of both,  with the emphasis on hose insulating, rather than exhaust.

 

😈

[BrendAn]

2 minutes ago, skippydiesel said:

Be careful Moneybox.

 

For the most part, Rotax do not endorse "lagging" of the exhaust system. Targeted shielding seems to be more acceptable.

 

I do a bit of both,  with the emphasis on hose insulating, rather than exhaust.

 

😈

Have to agree, lagging can increase heat of the exhaust itself.  airflow over the pipes takes the heat away 

[facthunter]

Note I didn't suggest lagging the exhaust. Use a baffle. The R9XXX motors need very good oil filtration and NO bubbles as the hydraulic lifters  depend on being fully pumped up with oil. Nev

Edited Friday at 10:16 PM by facthunter
spelling

[Thruster88]

Air in the hydraulic lifters causing a problem is a bit of a myth imo. At every oil change a filter FULL OF AIR is placed on the engine. On lycoming engines, a cylinder change or six requires the hydraulic lifters to be removed and cleaned of all oil so that the DRY TAPPET clearance can be checked and adjusted if necessary with different length push rods. The engine is then started often with a dry oil filter as well.

 

We probably shouldn't be having these discussions on the Zonsen engine thread. 

[BrendAn]

52 minutes ago, facthunter said:

Note I didn't suggest lagging the exhaust. Use a baffle. The R9XXX motors need very good oil filtration and NO bubbles as the hydraulic lifters  depend on being fully pumped up with oil. Nev

You weren't being replied too. Moneybox was.

[facthunter]

T88, You are wrong about the Air in Lifter s NOT being a Problem. The Lifting action is very destructive IF they are not Pumped Up. Refer to the FAA comments on Valve collet retainers failures. Nev

Edited Friday at 11:13 PM by facthunter

[Rapture]

On 10/1/2026 at 9:27 AM, Thruster88 said:

We probably shouldn't be having these discussions on the Zonsen engine thread. 

This.

 

We appreciate the observation about the proximity of the exhaust to the oil filter. Appropriate measures to reduce or negate the proximity of the exhaust to the filter are being adopted.  Future posts will show these initiatives.

[Blueadventures]

On 07/11/2025 at 1:00 PM, Rapture said:

Yes, the oil cooler is enhanced also and we will work out the required airflow.

It would have been a good development to increase the cross over pipe at the time of doing the casting patterns for the intake manifolds as there is good feedback from those that do such about the smoother idle and possibility of operating at 50% power in the instance of one throttle cable / connection breaking and engine going to full power on one carby.  Would have been a good change to what Rotax have there in my opinion. (I'm open / planning to increase my R ULS balance pipe i.d. size.)