Prop Extension Installation Instructions

Before You Install (All Extensions)

Proper installation of your new SABER Prop Extension starts with cleaning, deburring, and removing any raised metal on your engine flange, hub, flywheel, and lugs. Any raised metal on your engine flange, hub, or lugs could cause the Prop Extension to angle off from the center line and compromise parallelism between the Engine flange and the Prop Extension flange.

• Before bolting on, clean the threads of the engine flange lugs.
• If you have a Lycoming engine, ensure the Flywheel is installed before installing the Prop Extension.
• For constant-speed props, install an o-ring on the engine boss before installing the prop extension.
• The prop extension is manufactured with very tight tolerances. If the prop extension will not slide all of the way on, you may need to rotate the extension one or more lug holes to find the spot with the perfect fit.

Torque: Engine Flange to Prop Extension

Torque bolts using the crossing pattern (1, 4, 6, 3, 5, 2). Apply the torque in three equal steps (for example 10, 20, 30 ft-lbs for 3/8″ bolts) and at least one final pass at full torque.

Bolt size	Torque
8mm	14 ft-lbs
3/8″	30 ft-lbs
7/16″	40 ft-lbs
1/2″	50 ft-lbs

The torque value for the Propeller comes from the Propeller manufacturer. When requesting the torque value from the Propeller manufacturer, be sure to let them know whether the Prop Side of your Prop Extension is 6″ diameter or 7″ diameter. The Crush Plate and Prop Extension flange should be the same diameter.

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Solid (12-Hole) Prop Extensions — Less Than 3″ Long

1. Place the head of the extension-to-engine bolt in the counterbore (1-1/16″ diameter for 1/2″ bolts), which is located on the prop side of the extension.
2. The bolt head MUST be below flush, so the face of the extension makes full contact with the prop (or spinner bulkhead).
3. Apply BLUE Loctite (242) to engine bolts.
4. Use a thin washer under the bolt head for 1/2″ and 7/16″ bolts, and a standard AN washer for 3/8″ bolts.
5. Torque the bolts using the crossing pattern and values in the table above.

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Spool Prop Extensions — 3″ and Over

Follow the general steps and torque values above. For Continental and Franklin engine flange bolt-ups to a spool prop extension (excluding O-200), stack the hardware in this order, from the prop extension towards the engine:

1. Bolt head
2. Radius block
3. Prop extension flange
4. Engine flange
5. Washer
6. Lock nut

• NO WASHER IS TO BE PLACED UNDER THE BOLT HEAD OF THE 1/2″ BOLTS.
• DO NOT ALLOW THE BOLT HEAD TO TURN WHEN TORQUING THE LOCK NUT.
• The torque value it takes to turn the lock nut on the bolt must be added to the 40–50 ft-lb bolt torque.

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Spinner Notes (All Extensions)

Van’s Spinners

On some of Van’s spinner rear bulkheads, the center hole is not large enough for the bulkhead to properly seat on the prop extension due to the 1/32″ radius from the boss to the flange. To verify fit, slide the rear bulkhead onto the prop extension and check to see if it will seat flush on the flange. If there is a gap between the bulkhead and the prop extension, remove the bulkhead and use a deburring tool to open up the rear bulkhead’s center hole until it sits flat against the prop extension.

Composite Spinner Bulkheads

Composite spinner bulkheads should be wet sanded to obtain a flat surface on both sides. This is done to obtain complete surface area contact of the spinner with the prop extension and prop.