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Back in '93, when I was designing the Lycoming
engine installation for my IV-P, I was asking the same questions about
compression ratio. In researching the topic and talking to engineers at
Lycoming and Continental I uncovered an interesting fact; the exhaust
system is frequently considered part of the airframe and not part of
the engine. In those cases, the design of the exhaust system is the
responsibility of the aircraft manufacturer, not the engine
manufacturer. This caused the engine manufacturers to be very
conservative regarding detonation margins and therefore, compression
ratios.
My investigation and analysis lead to the conclusion that a higher
compression ratio (8.5 :1) and lower max manifold pressure (35 inches)
combined with intercoolers would result in an engine with superior
thermodynamic efficiency and lower exhaust temperatures. I hired a
retired Garret engineer (designer of the Mirage turbo installation) to
assist in selecting specific components (turbos, waste gate, controller
and relief valve). I designed an Oil Sump with integral engine mounts
and Oil Suction Strainer, a Oil Baffle Plate, Tuned Induction Plenum
and Intake Runners, Intercoolers, Intercooler Flow Combiner,
Turbocharger Mounting Brackets, Exhaust System, Baffling and ducting.
I integrated the components on a used IO540 K series engine core and
sent the assembly to Barrett Performance Aircraft for overhaul and
dyno testing. The BPA SAE calibrated dyno test data shows the engine
producing 360 HP at 2700 RPM and 35 inches MP. Power tests were run 150
degrees rich and TIT never exceeded 1500 degrees. Monty Barrett was
impressed by the engine and still features a picture of it in his print
ads in TAP. After nearly a dozen years and over 900 flight hours (and
several races) I can report that the engine is still going strong with
all of its original parts. Compression is still in the mid 70s. I
cruise at 75% power, 2,500 RPM, 28 IMP and 21 GPH.
A couple of years ago I shared the details of this installation and
flight experience with the engineers that went on to produce an STCed
high compression and sealed plenum modification for the Mirage.
My experience with the higher compression ratio and lower maximum
manifold pressure has been positive however I must caution that the
ultimate success of an installation is determined by the details of the
design, not the "big" parameters like compression ratio.
Regards
Brent Regan
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