1/2 VW (Half VW) Engine Conversion Plans for Ultralight or LSA Aircraft

Description: 1/2 VW Engine Plans Looking for a way to mount a 4-stroke engine to your ultralight or light aircraft? The economic solution is to take a full-case Volkswagon engine and modify it from four cylinders to using only the front two! There are various plans available from different sources for converting a full VW engine to a 1/2 VW engine, but they all, including our plans, specify removing the rear 2 cylinders, cutting the crankshaft and cam, and cutting the cylinder heads. There are then a multitude of various other modifications needed to seal up new openings created during the conversion and keep the engine leak free. Our new plans include over 30 pages of written instructions with additional pages of figures and drawings. There are even full scale templates for making the proper parts.The detailed plans and drawings which take you all the way through the conversion process to actually starting and running your creation. The plans come spiral bound in an easy to understand format printed on good glossy paper with vibrant color photos. Keep in mind that our plans call for using the entire case as this is the easier method and in many ways the preferred method for conversion. They do NOT specify how to do the cut-case type conversation. So why should you build a 1/2 VW Engine? Here are few good reasons: Parts are low cost and available via the internet or sometimes can be purchased in your home town.The engine is relatively lightweight. There is no expensive or heavy reduction drive or exhaust system to mount. Most of the time the crankcase is made of magnesium which is 33% lighter than comparable aluminum. If you build it well your engine will weigh 85-90 lbs. Engine HP can be from 28-37 hp depending on the internal parts used.The cylinders are aircooled, though truth be told most of the cooling comes from the oil. This means you don’t have to worry about a heavy or complex liquid cooling system.Below is a list of the content provided in our plans:Benefits of the Full-Case:Understanding the Plans:History of Plans:Work Area and Conditions:Engine Selection:Operating Specs:IgnitionCarburetor TypeSealants and Lubricants:Parts List:Suppliers:Tools and Services NeededSTEPS for Disassembly and Parts FabricationStep 1 - Drain oil, remove parts, separate the case1.1 - Clean the case and all partsStep 2 - Inspect the Crank CaseStep 3 – Prepare the CaseStep 4 - Painting the EngineStep 5 - Altering the Case5.1- Install studs and oil pickup5.2- Tap case for oil temp probe5.3- Bypass the oil cooler5.4- Plug rear main feed and plug lifter bores5.5 – Make case block off platesStep 6 - Cutting and altering the cylinder heads6.1 - Clean and inspect Cylinder Heads6.2- Remove and discard valves6.3- Install new valves6.4- Cut and drill the heads6.5 - Create the intake tubes6.6 - Welding the headsStep 7 - Alter Rocker Arms, Shafts and Covers7.1 - Cut and weld the rocker covers7.2 - Make exact measurements7.3 - Cut the rocker arm shaftStep 8 - Crankshaft cutting and altering8.1 - Disassembly and inspection8.2- Cut the crankshaft8.3- Make the counterweights8.4 -Weld the counterweights and oil feedStep 9- Machine the CrankshaftStep 10- Dynamic balancingStep 11- Mounting a prop HubStep 12 - Cut the CamshaftStep 13 - Creating the exhaust pipes STEPS For Re-assembly Of The EngineStep 1 - Crankshaft Assembly1.1– Crankshaft Preparation1.2 – Heated Crankshaft AssemblyStep 2 - Prop Hub InstallationExplanation of Installation2. 1 – Heat and install the prop hub2.2 - Install hub bolt2.3 - Drill hub bolt2.4 - Double check measurements2.5 – Hub Seal and Crankshaft end playStep 3 - Install Connecting RodsStep 4 - Oil pressure relief plungersStep 5 - Install Cam BearingsStep 6 – Install Crank BearingsStep 7- Close up the case7.1 - Install lifters7.2 - Apply Permatex Aviation Form-A Gasket #3 and close the case7.3 - Torque the case boltsStep 8 - Oil Pump and Oil Screen Installation8.1 - Oil Change gasket kit8.2 - Check Oil Pump Clearance8.3 - Put the pump into place8.4 - Install front coverStep 9 – Install Prop Hub SealStep 10 - Pistons and CylindersStep 11 - Set Deck Height for Proper CompressionStep 12 – Distributor Installation and Timing12.1 – Wire the switch and battery12.2 – Find TDC (top dead center)12.3 - Install distributor drive12.4 - Note Rotor Position12.5 - Set Static TimingStep 13 – Install Cylinder HeadsStep 14 – Set Valve Clearance/LashStep 15 – Install CarburetorsStep 16 – Install Fuel PumpStep 17 – Install Exhaust tubesStep 18 - Crankcase Breather & Oil FillerStep 19 – Oil Cooler Block Off Plate InstallationStep 20 – Counter Weight and Prop InstallationProp SelectionStep 21 – Fill with OilStep 22 – Initial StartupAdditional RecommendationsAdditional Troubleshoot TipsTroubleshooting Spark IssuesHow to Test an Ignition Coil for strong sparkCauses of Engine "Popping" or BackfireWiring DiagramDrawing Figures

Price: 25 USD

Location: Old Saybrook, Connecticut

End Time: 2024-08-18T04:13:54.000Z

Shipping Cost: 5.61 USD