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

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1/2 VW (Half VW) Engine Conversion Plans for Ultralight or LSA Aircraft:
$25.00

Looking for a way to mount a 4-stroke engine to your ultralight orlight aircraft? The economic solution is to take a full-case Volkswagonengine and modify it from four cylinders to using only the front two!There are various plans available from different sources for converting afull 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 variousother modifications needed to seal up new openings created during theconversion and keep the engine leak free. Our newplans include over 30 pages of written instructions with additional pages offigures and drawings. There are even full scale templates for makingthe proper parts.The detailed plans and drawings which take you all theway through the conversion process to actually starting and running yourcreation. 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 isthe 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 heavyreduction drive or exhaust system to mount. Most of the time thecrankcase is made of magnesium which is 33% lighter than comparablealuminum. If you build it well your engine will weigh 85-90 lbs. EngineHP can be from 28-37 hp depending on the internal parts used.
• The cylinders are aircooled, though truth be told most of thecooling comes from the oil. This means you don’t have to worry about aheavy 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:

Ignition

Carburetor Type

Sealants and Lubricants:

Parts List:

Suppliers:

Tools and Services Needed

STEPS for Disassembly and Parts Fabrication

Step 1 - Drain oil, remove parts, separate the case

1.1 - Clean the case and all parts

Step 2 - Inspect the Crank Case

Step 3 – Prepare the Case

Step 4 - Painting the Engine

Step 5 - Altering the Case

5.1- Install studs and oil pickup

5.2- Tap case for oil temp probe

5.3- Bypass the oil cooler

5.4- Plug rear main feed and plug lifter bores

5.5 – Make case block off plates

Step 6 - Cutting and altering the cylinder heads

6.1 - Clean and inspect Cylinder Heads

6.2- Remove and discard valves

6.3- Install new valves

6.4- Cut and drill the heads

6.5 - Create the intake tubes

6.6 - Welding the heads

Step 7 - Alter Rocker Arms, Shafts and Covers

7.1 - Cut and weld the rocker covers

7.2 - Make exact measurements

7.3 - Cut the rocker arm shaft

Step 8 - Crankshaft cutting and altering

8.1 - Disassembly and inspection

8.2- Cut the crankshaft

8.3- Make the counterweights

8.4 -Weld the counterweights and oil feed

Step 9- Machine the Crankshaft

Step 10- Dynamic balancing

Step 11- Mounting a prop Hub

Step 12 - Cut the Camshaft

Step 13 - Creating the exhaust pipes

STEPS For Re-assembly Of The Engine

Step 1 - Crankshaft Assembly

1.1 – Crankshaft Preparation

1.2 – Heated Crankshaft Assembly

Step 2 - Prop Hub Installation

Explanation of Installation

2. 1 – Heat and install the prop hub

2.2 - Install hub bolt

2.3 - Drill hub bolt

2.4 - Double check measurements

2.5 – Hub Seal and Crankshaft end play

Step 3 - Install Connecting Rods

Step 4 - Oil pressure relief plungers

Step 5 - Install Cam Bearings

Step 6 – Install Crank Bearings

Step 7- Close up the case

7.1 - Install lifters

7.2 - Apply Permatex Aviation Form-A Gasket #3 and close the case

7.3 - Torque the case bolts

Step 8 - Oil Pump and Oil Screen Installation

8.1 - Oil Change gasket kit

8.2 - Check Oil Pump Clearance

8.3 - Put the pump into place

8.4 - Install front cover

Step 9 – Install Prop Hub Seal

Step 10 - Pistons and Cylinders

Step 11 - Set Deck Height for Proper Compression

Step 12 – Distributor Installation and Timing

12.1 – Wire the switch and battery

12.2 – Find TDC (top dead center)

12.3 - Install distributor drive

12.4 - Note Rotor Position

12.5 - Set Static Timing

Step 13 – Install Cylinder Heads

Step 14 – Set Valve Clearance/Lash

Step 15 – Install Carburetors

Step 16 – Install Fuel Pump

Step 17 – Install Exhaust tubes

Step 18 - Crankcase Breather & Oil Filler

Step 19 – Oil Cooler Block Off Plate Installation

Step 20 – Counter Weight and Prop Installation

Prop Selection

Step 21 – Fill with Oil

Step 22 – Initial Startup

Additional Recommendations

Additional Troubleshoot Tips

Troubleshooting Spark Issues

How to Test an Ignition Coil for strong spark

Causes of Engine "Popping" or Backfire

Wiring Diagram

Drawing Figures

1/2 VW Motor Airplane Engine Conversion Plans Blueprints Instructions PDF USB

$20.00

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

$25.00

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

$25.00