Challenger Upgrades and Modifications

High Strength Stainless Steel U-Brackets	These Stainless U-Brackets are direct replacements for the aluminum U-Brackets supplied by the factory with every Challenger, and are far superior in strength. Extensive mechanical testing has been done, including tension, compression and cyclic load tests, all of which far exceed the initial testing done on the factory-supplied aluminum U-Brackets. Tension tests resulted in the 1.625" brackets exceeding 8,000 pounds of peak tension force (straight pull) before deformation (60% higher than the aluminum brackets). Tension testing of the 1.625" brackets at angles between 30 and 90 degrees also exceeded the tests of the aluminum brackets by between 19% and 117%, and compression testing of wing spar brackets exceeded 4,200 pounds. Cyclic load testing was done first at 85,000 cycles @ 2,000 pounds of tension, with no deformation, cracks or failure. A second cyclic load test was then conducted for 250,000 cycles @ 2,000 pounds of tension and again resulted in no deformation, cracks or failures. The Stainless U-Brackets are slightly heavier than the aluminum, but the weight difference is minimal. Each 1.625" stainless U-Bracket is 2.96 ounces heavier than the aluminum bracket (a set of 4 stainless 1.625" U-Brackets will add a total of only 11.84 ounces to your Challenger). The 2" U-Bracket is 3.21 ounces heavier than a 2" aluminum bracket (a set of 4 stainless 2" U-Brackets will add a total of only 12.84 ounces to your aircraft). If you replace all 8 brackets, you will add a total of just over 1.5 pounds to the empty weight of your aircraft (the equivalent weight of about 1 quart of fuel). Click Here to Order
Challenger Nose Cone with Access Hatch	If you are building a Challenger, you will love this option (if you already have a Challenger, see the Retrofit Nose Cone Hatch below) This new style nose cone fits all Challenger II models (CH-2, CH-2 Special, XS-50, XL-65 and LSS). The Nose Cone Access Hatch provides easy access to your panel, battery, strobe driver, ELT, other electronics, rudder cables, etc. After years of retrofitting the hatches into the standard nose cones, we now offer the hatch assembly molded in during the manufacturing process, for precision fit and finish. $550. Pictures
Challenger Nose Cone with Access Hatch - Retrofit Kit	Same as above, to be retrofitted onto any 2 seat Challenger nose cone that does not already have an access hatch. $135. Pictures
Shock Absorbing Nose Gear	This great option is a direct retrofit replacement for the existing nose gear. Unlike some of the expensive gas shock designs and other spring shock styles that require welding, this upgrade installs in about 30 minutes and requires no welding. Includes new nose fork. For standard 5" wheel: $165 (also available for 6" nose wheel: $195). Pictures
Heavy Duty Nose Gear Shaft (pre-cut and pre-drilled for Shock Absorbing Nose Gear Upgrade)	These Heavy Duty Nose Gear Shafts are sleeved with 4130, which is pressed into the shaft. They weigh only 4 ounces more than the previously available heavy wall aluminum nose gear shafts (no longer produced by the factory). Steering pushrod tangs included and pre-installed. If using the fixed (non-shock absorbing) nose fork, order the undrilled Heavy Duty Nose Gear Shaft below. $165
Basic Hydraulic Brake Package, With 2 Ply Tires	Complete retro-fit or new installation brake package, features Black Max hydraulic brake system, 6 X 4 Aluminum Wheels, with 13 x 5 x 6 imported tubeless 2 Ply tires, all installation hardware, plus new axle weldments. This package allows you to use your existing 6" Challenger main wheel fairings (when using our Wheel Fairing Installation Kit, listed below). $544 Pictures
Basic Hydraulic Brake Package, With 4 Ply Tires	Same package as above, upgraded to 13 x 5 x 6 tubeless 4 Ply Carlisle Tires. $624
Fiberglass Gear / Basic Hydraulic Brake Package	Includes all items listed above, plus fiberglass gear legs. $744 Pictures
Fiberglass Gear / Tundra Tire Brake Package with 4 Ply Tires	Includes all items above, plus 15 x 6 x 6 tundra type tires (4 Ply, Carlisle brand, tubeless). $794 Pictures (The wheels and tires in this package are to large to use with your existing 6" Challenger main wheel fairings. To use wheel fairings on this package, you will need Tundra Style Wheel Fairings, listed below.)
5" Polished Aluminum Nose Wheel / Tire	Complete 5" nose wheel assembly that matches the one piece wheels in all of the wheel/brake packages above, and comes with the complete hub/bearing assembly, 4 ply tubeless tire and new axle and wheel spacers. Direct replacement for your factory Challenger 5" plastic or aluminum nose wheel. $142
6" Polished Aluminum Nose Wheel / Tire	Complete 6" nose wheel assembly that matches the one piece wheels in all of the wheel/brake packages above, and comes with the complete hub/bearing assembly, 4 ply tubeless tire and new axle and wheel spacers. Direct replacement for your factory Challenger 5" plastic or aluminum nose wheel. $163
Wheel Fairings for Tundra Style Tires	Designed for our 15 X 6 X 6 Tire packages above, these extremely lightweight fiberglass wheel fairings (only 2.5 lbs each), provide streamline drag reduction and increase airspeed. Available in standard finish (ready to sand and paint) or with high gloss polished colored gel coat (order below) in a variety of colors. Sold per fairing. $169 Pictures
Wheel Fairing Installation Kit	Includes all of the mounting brackets and other hardware needed for easy installation. Sold per fairing. $19
Wheel Fairing High Gloss Gel Coat Finish	If you don't want to paint your fairings, consider this upgrade. High Gloss colored gel coat is used when the fairings are made, and then polished to a high gloss shine. Available in the following colors: Black, White, Yellow, Red, Blue, Green. These fairings are polished to a high gloss shine, and do not need to be painted. $30 Pictures
Metal Flake Finish	Optional metal flakes can be molded into the colored gel coat. To order a metallic finish, select one of the 4 gel coat colors above, then choose your flake color. Metal Flake Colors: Blue, Red, Gold, Silver, Orange and Pearl. $40
Hinged Front Windscreen	If you have grown tired of sliding in the front seat of your Challenger by working your way around the windscreen, this is exactly what you need. Retrofit modification that installs easily to your existing windscreen in about an hour, and allows direct access to the front seat. Includes everything needed to install, pre-formed tubes, complete instructions and detailed photos. You will wish you installed this optional a long time ago! $145 Picture
Custom Upholstered Seats	Available in a variety of colors, these plush fabric upgrade seats drastically change the appearance and comfort of your Challenger. Custom embroidery ("Challenger" your name, N number, etc.) available for a small additional cost. $275 per seat. Picture
Cabin Heater.	We make them here, according to Quad City plans. Includes the heat collector, butterfly apparatus, single cockpit control, flange and ducting for the cockpit. These heaters are complete kits, and ready to install on your aircraft. If you order the heater kit for an aircraft we are assembling, we will cut the inlet hole into the aluminum engine area covers, fit a flange in the hole and supply a cover plate for the hole when the heater is not in use. We also install plate nuts in the engine shroud, allowing quick, easy and secure installation of the collector. When you get ready to install your heater, simply remove the cover plate, attach the collector, screw in the flange and attach the hose as required. Cost is $155. Picture
Nose Gear Support Plate.	Nose Gear Support Plate. Fabricated out of aluminum plate, and provides additional lateral support for the nose gear. Helpful in side load landings (not that you would every do that). Cost is $65. Picture
Swivel Tail Wheel.	Standard tail wheel is fixed, so when the plane is on the ground you must pick up the tail to move it around. It moves straight forward and straight back without any problem, but is a little awkward to turn. The swivel tail wheel is $20. Picture
Aluminum Support for Front Seat Back.	Additional Aluminum Support for Seat Back of Front Seat. Standard design has a small piece at the top area of the seat, and another small piece near the bottom. We suggest adding another piece to cover the entire seat back area. Cost is $65.
Aluminum Seat Back with Cargo Pocket for Rear Seat.	Aluminum Seat Back with Cargo Pocket for Rear Seat. The standard configuration for the rear seat is a small piece of thin wood, hinged at the bottom, which serves as a support for the rear seat back, and allows access to the fuel tank. We suggest replacing the wood with an aluminum door, which we fabricate to include a small pocket on the rear that will hold 3 quarts of engine oil (or other small items). Cost is $110. Picture Picture 2
Aluminum Engine Area Bulkheads.	The area in front of and below the motor of the Challenger is covered with fabric on the standard planes. I suggest installing aluminum in place of the fabric on both surfaces. It ads very little weight, but is much easier to wipe down (there will be oil on these areas frequently) and it looks much looks better (in our humble opinion). It also helps if you ever drop a spark plug while changing them (no fabric to puncture), and makes it much easier and cleaner looking to run your wiring harnesses through. Cost is $95, which includes cutting all necessary holes for wiring harnesses and associated grommets. Picture
Lower Wing Rib Upgrade Kit	This kit contains10 lower wing ribs (5 per wing), plus all gusset plates, rivets, fabric rivets, 1/2 Rib Reinforcing Tape and fabric rivets necessary for installation. Allows you to have fabric attachment points on the lower wing skin, and also adds to the overall appearance of the plane. Not for use with sailcloth or Mylar wing covering. Cost is $225.
Aluminum Instrument Panel.	Aluminum Instrument Panel. As opposed to the standard wood one with the kit. We use .032 or thicker aluminum (depending on the number of instruments installed), with "L" reinforcement stiffeners where necessary, and with a bend to vertical towards the bottom (on the standard panels). Painted the same color as your plane or trim, or black, whatever you want. Cost is $95 for the standard size panel, cut for your instruments. We can extend the bottom of the standard panel an inch or two, to allow for more instruments, if necessary. Larger sizes are available, based on your instrumentation. Picture
Removable Nose Cone Panel.	Removable Nose Cone Panel. The standard installation for the fiberglass nose cone is to permanently attach it to the airframe. The problem with this is the fact that the battery and Hotbox usually need to go in the front of the nose, making it difficult to service them if necessary. It is also difficult to get to the rear of the instrument panel with a permanently attached nose cone. We can cut a panel in the top front of the nose cone, allowing access to the battery, panel and Hotbox, as well as nose gear assembly. The access panel is approximately 12’ wide and 18" long (front to rear of aircraft), and held in place with stainless machine screws (which can be painted to match) and plate nuts. I have the panel cut out using a jig, and then a lip is glassed on the inside to install the plate nuts to, and support the panel. The cut out panel is reused as the access door. It costs $225 for the plate nuts, screws, a considerable amount fiberglass work (done by our friend and co-worker John, whose wife Patti cracks the whip and makes him do them to her exacting specifications ;-)). Picture
Battery and Hotbox Mount Structures.	Battery and Hotbox Mount Structures. Required for aircraft we assemble. We extend the front of the longerons about 10" and make a platform out of extruded "L" angle to support the battery and Hotbox. The battery then sits in front of the rudder pedal stop bar. The Hotbox is mounted above and aft of the rudder pedals, in front of the instrument panel. Mounted here, both are out of the way, and do not get kicked or bumped when entering or exiting the aircraft. We can mount the battery in the rear of the aircraft, behind the fuel tank, but personally do not feel that is a good combination in an enclosed area. You also have a 17 pound battery in the aft CG position when mounted in the rear. We can mount the Hotbox in one other place in the nose, but it will protrude from the side of the airframe (inward) in front of the pilot (in the area of your knees, and usually in the way. Space is limited in these airplanes). If you choose to have the access panel cut into the nose cone, the battery and Hotbox are directly below the panel opening, allowing easy access to the connections on both. Cost is $90 (if using electric start) and $55 (if just using Hotbox without electric start). Picture
Kuntzleman Wingtip Strobes.	Very light weight, effective and reliable. They operate with or without a battery (via A/C lighting coil lead if no battery system). We install them running almost totally through lightweight rigid plastic conduit (which is installed in the wings), to reduce the chance of chafing to the wiring harness. $285 including the conduit and installation.
Lowered Engine Area Tube.	This is a little hard to explain. There are 2 tubes below the engine area that are part of the fuselage. They are both parallel with the ground, and the top one sits about 6" below the bottom of the engine. I have previously moved the rear of the upper tube at an angle down to the lower tube, thus allowing several extra inches of space below the motor. As the spark plugs are on the bottom (motor is inverted) it makes changing them easier. It is sometimes a little difficult with the standard set up. (The area above this upper tube is one of the two areas we suggest replacing with aluminum, as mentioned above). There is no cost for this modification
Hobbs Meter.	The EIS has an hour meter for both current flight time, and cumulative time, but you can not see it unless the EIS is on (motor running if no electrical system/battery). Many customers like the Hobbs so they can look at the panel any time and see total hours. Cost is $41.
Kuntzleman Hot Box.	We highly recommend this upgrade and it is a required item for aircraft that we are assembling. In essence it is a pre-wired electrical component, with fuses, terminals, etc., allowing easy installation of the EIS, engine electrical system, etc. It's greatest benefit is that it allows you to add electrical components later (landing lights, radio power, GPS power, intercom, etc.) by simply attaching to the existing electrical connections. That saves you many headaches later on, so you do not have to run power leads, wiring harnesses, etc. to the motor a later time. They cost $240 and we need to know if you are going to use electric start before we order it.
Pitot Tube.	Pitot Tube. We fabricate these out of aluminum tube with vinyl tubing attached to it and run to the A/S indicator lead. Normally they are installed on the lower surface of the wing at the strut, or fiberglassed into the point of the nose cone. Your choice. Cost is minimal, and depends on location (length of tubing required). If you have a fiberglass nose cone, I suggest the nose cone installation. We do not paint the tube, but we do cover it with florescent electric shrink tubing, so most blundering non-aircraft owners at your next fly-in will not knock it off your plane. Cost is $45.
Exhaust Clamps.	Exhaust Clamps. The standard clamping devices for the Rotax muffler are a series of springs that are often problematic. They often break, and can damage your prop if they fall off in flight. The exhaust brackets in this modification are made of stainless steel, use all AN hardware, increase safety and reduce the possibility of expensive prop damage by a broken spring. Cost is $50.00 each, and 2 are required. Trust us, you want this option. Picture
High Density Seat Cushions.	Suggested for the bottom cushion of the pilots seat (or both, if you like your passengers that well). Good for increasing the comfort level on longer flights (1.5-2 hours or more). $19 per seat, and worth every penny of it.
Aileron Gap Seal.	Aileron Gap Seal. We use a 3M material, which does not crack or dry out. Cost is $11 for enough material for both wings. This is not required on Sailcloth or Mylar wings.
Battery.	For Electric Start package. Sealed, no maintenance, 12 volt, 18-20 amp, usually mounted in the nose. Mounting requires building a bracket to support the battery, and attach it to the airframe (front of longeron tubes, forward of rudder pedal stops). Cost for battery and mounting hardware is $105, installed, and the mount below is necessary.
Key Switch.	(Required for Electric Start). Has Off, Left, Right, Both and Start positions. With 2 keys. $186.
Slip Indicator.	2-1/4 inch instrument. $61.
Magnetic Compass.	2-1/4 inch instrument, unlighted, panel mount. $109
NGK BR8EIX Plugs.	These NGK Iridium plugs are specifically designed for use in inverted motors, and foul less often. $11.
Toggle Switches.	You will need one as a master, and others for your electrical equipment. $5 each, installed.