After completing solid MDF case patterns, I fabricated the 6 individual molds that produce sand molds and cores for each case half. The right half molds were taken to a foundry in SoCal where the first prototype case half was cast. It came out a bit heavy so with the knowledge gained, I fabricated the left half molds incorporating the necessary changes to produce a light weight but strong case.
Next, I contracted with CP Carrillo to custom build light weight, forged pistons w/rings that would fit the O-200 cylinders. Additionally, custom “H” beam rods were designed that would give the Pegasus O-100 a 9:1 compression ratio. The decision to scrap the Continental rods and pistons was two-fold: 1) it was an issue with weight – the new pistons and rods are about 2 lbs per cylinder lighter (and 10 times stronger) than stock and, 2) with complete control of the weight of the rotating and articulating mass, I can guarantee the production engines will be balanced and smooth running across the production run. I’m thinking and shooting for “Sewing Machine Smooth”.
