Ultralight Aircraft Parts

Brolga Ultra-Prop

Competition Aircraft: Composite Propellers for Ultralight Aircraft Since 1983

Ultimate Propellers for Ultralights

Brolga Ultra-Prop High performance Brolga blades are no longer available through Competition Aircraft. The manufacturing rights were purchased by Bolly Props in Adelaide, Australia (www.bollyaviation.com.au). Contact them for replacement blades. We still carry the hubs, pitch blocks, spinners, and hardware.

High performance Brolga Ultra-Prop blades are available for larger, faster, higher horsepower ultralight aircraft. The blades are made with carbon, and glass fibers over a foam core. Blades have a high performance airfoil and optimum twist to give superior, high-speed performance.

These propellers utilize the same proven hub and pitch block system as our standard props, with blades made with glass reinforced nylon. However, the hubs and pitch blocks are modified to use 5/16" hardware in place of the 1/4 " on the standard Ultra-Prop.

Contact us for our recommendations for other applications.

Pricing

Brolga hub half (5/16" holes) $50
Brolga pitch blocks $10/per
Brolga spinner kit $60
5/16 inch hardware (two bolts, nuts, and washers) $5

Selected Brolga Recommendations

Engine

68 Inch
66 Inch
60 Inch

Rotax 912

3-blade, 12 or 13°

3-blade, 14 or 15°

4-blade, 16 or 17°

Rotax 618
(2.58/2.62)
(3.0)

3-blade, 14°
3-blade, 18° or
4-blade, 14°

3-blade, 16°
4-blade, 16°

4-blade, 18°

Rotax 582
2.58/2.62)
(3.0)

3-blade, 12°
3-blade, 16°

3-blade, 14°
3-blade, 18°

4-blade, 17°

Rotax 532
(2.58/2.62)
(3.0)

3-blade, 11°
3-blade, 15°

3-blade, 13°
3-blade, 17°

4- blade, 16 or 17°

Rotax 503
(2.58/2.62)
(3.0)
(3.47)
(4.0)

2-blade, 12° or
3-blade, 9°
3-blade, 12 or 13°
3-blade, 16°
4-blade, 18°

3-blade, 11°
2-blade, 14 or 15°
3-blade, 18°

3-blade, 17° or 4-blade, 11 or 12°
4-blade, 18°

Rotax 447
(2.58/2.62)

2-blade, 10°

2-blade, 12°

3-blade, 15° or
4-blade, 11°

Assembly and Care of the Brolga Ultra-Prop

The Ultra-Prop with the Brolga blades is assembled the same as the standard nylon bladed prop as described and illustrated in the Ultra-Prop Assembly, Installation, Operation & Maintenance Instructions with the following exceptions or changes.

1. The blade mounting hardware is 5/16" instead of 1/4".

2. Two washers are used under the nut and one under the bolt head.

3. Torque bolts to 124-150 inch lb.

4. Check and retorque bolts to above values using the following schedule:
  • after first run
  • after 1 hour of operation
  • after 2 hours of operation
  • after 4 hours of operation
  • after 8 hours of operation
  • after every 20 hours of operation
Brolga Ultra-Prop

Maintenance

The propeller has no definite life. An expectation of 2,000+ hours is not unrealistic, provided the proper inspection and maintenance schedule as follows is adhered to:

1. Every 20 hours, retorque blade bolts to 124-150 inch lb. And prop mounting bolts to appropriate value in table 2.

2. Every 200 hours, dismantle prop and inspect all parts for cracks and/or wear. Visually check the bolts and bolt holes and the "spline" area where the blades and pitch blocks are joined. No wear or elongation is allowed. Patches of surface corrosion on the blade bolts dictates replacement. Replace any defective parts. Inspect the blades for water ingestion or delamination.

3. Any prop strike is cause for a complete disassembly and inspection as described in #2 above. The presence of any stress fracture emanating from the bolt holes in the blades dictates blade replacement.

4. Every 1000 hours, replace all hardware.

Blade Damage Repair

Small chips along the entire blade length (up to 3/16" long and extending no further than 3/32" from the blade edge) may be filled with a high quality, slow setting epoxy resin after thorough cleaning and degreasing with MEK. The "five-minute" type epoxies are not acceptable.