So the last few months I've been keeping reasonably busy on my next "big" project. Just about as far away from diesels as you can get. I've learned a lot, met a lot of challenges and have beaten each challenge down in turn. Moment of truth should be this weekend I hope, but it's looking good so far and I figure some of you guys might find it interesting.

I figure 49% of you guys will figure I'm crazy
49% figure I'm psychotic
And about 2% in the "That's sweet!" category

OK - so I'll admit there's certainly some crazy aspect. I don't think I've ever modified and voided warranties for so many things in 1 project in my life!

Hint 1: It's not terribly big.
<img src="http://www.hightechome.com/Project/VW 010.jpg" width="640" height="480">

Hint 2: That's not a broken crankshaft
<img src="http://www.hightechome.com/Project/VW 005.jpg" width="640" height="480">

That's right, *crazy alert*... I bought a brand new $300.00 stroker crank, pulled it out of the box, said "nice crank" and chucked it up in a chop saw. So then I had to move the thrust bearing from the flywheel end up to the front of the crank, and doing that required some machining of the thrust bearing, as well as machining of the cam gear. Then had to get the crank balanced, and that was a bit of an issue as it was too small to fit on *any* engine shops balancing machine that I talked to for about 100 mile radius. So then I worked with the engine shop to build an attachment for the balancing machine so I could balance the crank.

So, buy a stroker crank, then cut it in half. Turned into a bunch of massaging of other engine parts to swing the stroke...because crankshaft, connecting rods and camshafts all trying to occupy the same spot at the same time is a bad thing!

<img src="http://www.hightechome.com/Project/VW 009.jpg" width="640" height="480">

Moving on... No 1/2 of an engine would be complete without cutting the cylinder heads in half! That of course requires some TIG welding and machining, but I'd call it one of the easiest parts of this project darn near!
<img src="http://www.hightechome.com/Project/VW 018.jpg" width="640" height="480">

Where I'm at now: Any guesses what those stubby exhaust pipes are? hint- look under your kitchen sink! chromed wall pipe section for a sink p-trap. It's the perfect size, and it's chromed for some class! By the way, that's a brand new distributor that I took apart and ground 2 lobes off to make a 2 cylinder distributor. More warranties out the window!

<img src="http://www.hightechome.com/Project/VW 020.jpg" width="640" height="480">

So tonight I CC'ed my heads and measured my deck height. With no cylinder spacers I'd get 11.1:1 compression... youch! I have spacers so I can run 9.1:1, 8.5:1 and 8.0:1 compression ratio. I can't decide yet. It'll run on premium fuel so I should be OK with 9.1:1, but I think I'm leaning towards 8.5:1 or 8:1 I don't want to stress the engine out as dependability is foremost and longevity and power come second.

Soo... Why cut it in half if your worried about dependability you say? Simple.. it needs to be as light as possible. Why? Because it's going in one of these!

YouTube - &#x202a;Joe Spencer & Putt Putt&#x202c;&rlm;

So whaty'all think?

 

That is some project.
What is it? Some sort of Lycoming?
I think I have to agree that you may have voided at least some of the warranties.

 

I'll admit at first i was in the "That's crazy" group. But after seeing what your plans were i think its neat.

That engine looked like it would have been very light to start with, so how much of the engine weight did you lose?

 

It's not crazy, it's VW. The one thing I question is setting the endplay. And what are you going to do about a thrust bearing? Also what carb do you plan on using? I guess you'll be using an oil cooler off the front pump cover since the ports are in the rear of the top of the case.
You know there is a 2 cylinder horizontal opposed air cooled already made that's similiar to a VW design? You could use a BMW motorcycle engine.

I'd like to see how this project comes out.

 

I'm in the 2%! That looks awesome! I takes a real mechanic to make something!

 

End play is already dealt with. As you know the stock VW thrust bearing is at the flywheel end, which I cut off and am using for a paperweight. I moved the thrust bearing to the 2nd bearing (though VW would call it the 3rd bearing). I had to back cut the bearing shell a little bit so it'd slide onto the block's bearing web, then to fit the thrust bearing in with the thrust washers I had to back-cut a step on the camshaft timing gear to make a little more room. The propeller will always be pulling on the crank so all the thrust wear goes against the crank and the cam gear side will only ever see wear perhaps when starting the engine.

<img src="http://www.hightechome.com/Project/VW 003.jpg" width="640" height="480">

Stock oil cooler location is retained yet, however most who have built this engine haven't needed to use an external oil cooler. I retain full VW oil capacity, but I only have half the moving parts. I'll be putting in an oil cooler bypass and if I need a cooler on it I can just bolt one on.

Carburetors will be a pair of 32mm Mikuni round slide carbs. I may have to drill out or increase the jetting of them a tiny bit, but if I'm lucky all I'll have to do is peel off the "not for aircraft use" sticker

The BMW bike engine had actually been mentioned as a candidate before. It does look like a good engine. However the VW is much easier to get parts for. And cheaper.

Haven't gotten it entirely assembled yet but I figure it should be in the ballpark of about 90 lbs dry. I think as 4 cylinder bare they ran about 180 lbs. If you look close I cut off the transmission mounting flange to leave only the 4 attach points, I back cut a bit of the cam gear to save some weight, drilled holes in it to save weight. Cutting the crank in half and getting rid of 2 cylinders/pistons/rods and cutting the heads in half is a good savings as well. I have aluminum plates to bolt over the extra cylinder holes.

 

wow !!! that will be one hell of a project!!!

 

I think it is cool. Just don't crash it into someone's house, which seems to be a favored thing to do lately among small aircraft pilots.

 

hey if u crash and die can i have ur idi

 

That shouldn't be a problem! Crashing is last on my list! And that thing is so light it'd pretty well bounce right off. To be an ultralight, the aircraft must weigh 254lbs or less (not counting fuel), max speed of 60mph and land at 25mph or slower. No training or license requirements to fly one, but I've had my pilots license for a few years now. In fact if you look in the background of the picture with the nearly assembled engine, you'll see a white colored assembly (PVC plastic coating to protect the aluminum). That's the other airplane I'm building - a Mustang II. That'll use a 200hp engine and fly at 200-230mph. The ultralight is just a much cheaper plane to build in the mean time.

Here's what the Mustang II looks like.
<img src="http://www.mustangaero.com/images/Mustang%20II/big_pics/Crawford1.jpg" width="640" height="400">

Problem is I figure that one will run me about $50,000.00 to finish yet, which is why I'm building the little weed hopper for fun right now When I got my pilots license my flight instructor said "Welcome to avaiation...you will now forever be broke" So true! Last fill up this weekend in the Cessna I paid 5.75/gallon...ick.

 

LOL Sure Joe, just remember it's got so much blow-by I'm looking for another IDI block myself!

 

good at least ur wireing is good lol

 

I don't care who you are, that's friggin awesome!

I WISH I had half your skills!

Cudos for the creativity, and reps for sharing!

Post more as it comes along!

 

Flight... man that project took me back to my first job. Avionic instrument tech, got to Fly every other day. I helped build 3 ultras, such fun! Love to see the progress as you continue. I piloted a Bonanza V-tail, not a mustang 2 but still fun stuff.

I would put you in the "crazy" catagory, but if your not you would not be building this thing

 

Ok, now that right there is funny! Joe, I had no idea you were a poet!LMAO

swooshcmk, even if was in the other 98% I would dare not give you a hard time for that considering some of my own projects (ask joe). Anyone can get a new crank out of the box, follow some instructions and have an engine running with a few grand spent. Not everyone can or will go to that length and create new parts for a one of a kind engine like that. Some will try, most never bother.

Actually, it seems most are in the 2% minority of freaks here anyway so thanks for sharing