Computer Certainty developed this alternative starter bracket for our own use on a Lycoming O-235 back in 1986. We did so for several reasons:

 
1. At 22 pounds the original Delco starter supplied by Lycoming is exceptionally heavy.

2. At $270.oo (in 1986!) for an exchange-rebuilt (of questionable heritage) it was far too expensive.

3. The current draw is needlessly high. Modern, geared starters use much less current.

4. The Delco is simply not as powerful in spite of it's higher current consumption.

5. The user frequently loses use of the A/C for days or weeks waiting for the replacement part.

 
 

By contrast, the CCI replacement produces a net weight saving  of 14.5 pounds!  (There is no need for a separate starter relay. This unit has it's own). It's a geared starter, popular on Toyotas, and can be installed without modifications to the engine. A rebuilt unit is usually in-stock at most automotive parts jobbers.  A used unit, in excellent condition, was purchased recently from a salvage yard for $50.oo! At 1.9 horsepower, it's powerful in spite of it's light weight. Although it barely weighs 9.2 pounds installed, the prototype spun a newly “blue-printed” Lycoming IO-540 engine, equipped with high compression pistons, so fast we thought we'd forgotten to install the spark plugs!

The documentation consists of 5 CAD generated drawings,  4 pages of written  instructions and 1 BOM with soures. People sometimes assume that anything that requires that much explanation has to be difficult. Not so! We believe that clarity is important and that it's better to provide too much detail than not enough. What you get with our starter plans are simply the consequence of our efforts to be thorough. We believe that the starter weldment is a lot simpler to render than many devices that homebuilders typically create for their aircraft. (Note: this design is not TSO'd for use in certificated aircraft)

As for the time required to build, that varies so greatly from one individual to the next that it's pointless for any designer to even suggest how long it should take you. Regardless of ability, if you do not have access to at least a good drill press, and a good band saw, it could be labor intensive. Here is what one user wrote:
 

"I used your design for a starter bracket and a toyota starter. Pretty slick.  The whole thing weighed in at 10.4 pounds.  So its actually pretty competitive with whats out there on the market for more than $300.oo.

I think you could taxi with just the starter....."

         Paul L. Flint

Note, the tooth pattern on this starter only works one of two specific Lycoming ring gears. Lycoming engines use ring gears either with 122 or 149 teeth with the 122 being the most popular. This installation is optimized for the 122 tooth ring gear which is the gear that Lycoming used on all the O-235's, the larger 0-540's and O-720's at the time the design was developed. To use this design, some engine owners ( O-320 and O-360) will need to switch to the 122 tooth ring gear.

        COMPUTER CERTAINTY, INC. P.O. BOX 494, MILFORD, NJ

To download the free drawings and install instructions click here: Starter Adapter.zip
 

To E-Mail us, Click here:

     CCI reserves the right to change specifications at any time without notice

Computer Certainty developed this alternative starter bracket for our own use on a Lycoming O-235 back in 1986. We did so for several reasons:

 
1. At 22 pounds the original Delco starter supplied by Lycoming is exceptionally heavy.

2. At $270.oo (in 1986!) for an exchange-rebuilt (of questionable heritage) it was far too expensive.

3. The current draw is needlessly high. Modern, geared starters use much less current.

4. The Delco is simply not as powerful in spite of it's higher current consumption.

5. The user frequently loses use of the A/C for days or weeks waiting for the replacement part.

 
 

By contrast, the CCI replacement produces a net weight saving  of 14.5 pounds!  (There is no need for a separate starter relay. This unit has it's own). It's a geared starter, popular on Toyotas, and can be installed without modifications to the engine. A rebuilt unit is usually in-stock at most automotive parts jobbers.  A used unit, in excellent condition, was purchased recently from a salvage yard for $50.oo! At 1.9 horsepower, it's powerful in spite of it's light weight. Although it barely weighs 9.2 pounds installed, the prototype spun a newly “blue-printed” Lycoming IO-540 engine, equipped with high compression pistons, so fast we thought we'd forgotten to install the spark plugs!

The documentation consists of 5 CAD generated drawings,  4 pages of written  instructions and 1 BOM with soures. People sometimes assume that anything that requires that much explanation has to be difficult. Not so! We believe that clarity is important and that it's better to provide too much detail than not enough. What you get with our starter plans are simply the consequence of our efforts to be thorough. We believe that the starter weldment is a lot simpler to render than many devices that homebuilders typically create for their aircraft. (Note: this design is not TSO'd for use in certificated aircraft)

As for the time required to build, that varies so greatly from one individual to the next that it's pointless for any designer to even suggest how long it should take you. Regardless of ability, if you do not have access to at least a good drill press, and a good band saw, it could be labor intensive. Here is what one user wrote:
 

"I used your design for a starter bracket and a toyota starter. Pretty slick.  The whole thing weighed in at 10.4 pounds.  So its actually pretty competitive with whats out there on the market for more than $300.oo.

I think you could taxi with just the starter....."

         Paul L. Flint

Note, the tooth pattern on this starter only works one of two specific Lycoming ring gears. Lycoming engines use ring gears either with 122 or 149 teeth with the 122 being the most popular. This installation is optimized for the 122 tooth ring gear which is the gear that Lycoming used on all the O-235's, the larger 0-540's and O-720's at the time the design was developed. To use this design, some engine owners ( O-320 and O-360) will need to switch to the 122 tooth ring gear.

        COMPUTER CERTAINTY, INC. P.O. BOX 494, MILFORD, NJ

To download the free drawings and install instructions click here: Starter Adapter.zip
 

To E-Mail us, Click here:

     CCI reserves the right to change specifications at any time without notice