1/2 VW (Half VW) Engine Conversion Plans For Ultralight Or LSA Aircraft

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1/2 VW Engine Plans<br>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.<br>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<br>cut-case<br>type conversation.<br>So why should you build a 1/2 VW Engine? Here are few good reasons:<br>Parts are low cost and available via the internet or sometimes can be purchased in your home town.<br>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.<br>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.<br>Below is a list of the content provided in our plans:<br>Benefits of the Full-Case:<br>Understanding the Plans:<br>History of Plans:<br>Work Area and Conditions:<br>Engine Selection:<br>Operating Specs:<br>Ignition<br>Carburetor Type<br>Sealants and Lubricants:<br>Parts List:<br>Suppliers:<br>Tools and Services Needed<br>STEPS for Disassembly and Parts Fabrication<br>Step 1 - Drain oil, remove parts, separate the case<br>1.1 - Clean the case and all parts<br>Step 2 - Inspect the Crank Case<br>Step 3 – Prepare the Case<br>Step 4 - Painting the Engine<br>Step 5 - Altering the Case<br>5.1- Install studs and oil pickup<br>5.2- Tap case for oil temp probe<br>5.3- Bypass the oil cooler<br>5.4- Plug rear main feed and plug lifter bores<br>5.5 – Make case block off plates<br>Step 6 - Cutting and altering the cylinder heads<br>6.1 - Clean and inspect Cylinder Heads<br>6.2- Remove and discard valves<br>6.3- Install new valves<br>6.4- Cut and drill the heads<br>6.5 - Create the intake tubes<br>6.6 - Welding the heads<br>Step 7 - Alter Rocker Arms, Shafts and Covers<br>7.1 - Cut and weld the rocker covers<br>7.2 - Make exact measurements<br>7.3 - Cut the rocker arm shaft<br>Step 8 - Crankshaft cutting and altering<br>8.1 - Disassembly and inspection<br>8.2- Cut the crankshaft<br>8.3- Make the counterweights<br>8.4 -Weld the counterweights and oil feed<br>Step 9- Machine the Crankshaft<br>Step 10- Dynamic balancing<br>Step 11- Mounting a prop Hub<br>Step 12 - Cut the Camshaft<br>Step 13 - Creating the exhaust pipes<br>STEPS For Re-assembly Of The Engine<br>Step 1 - Crankshaft Assembly<br>1.1<br>– Crankshaft Preparation<br>1.2 – Heated Crankshaft Assembly<br>Step 2 - Prop Hub Installation<br>Explanation of Installation<br>2. 1 – Heat and install the prop hub<br>2.2 - Install hub bolt<br>2.3 - Drill hub bolt<br>2.4 - Double check measurements<br>2.5 – Hub Seal and Crankshaft end play<br>Step 3 - Install Connecting Rods<br>Step 4 - Oil pressure relief plungers<br>Step 5 - Install Cam Bearings<br>Step 6 – Install Crank Bearings<br&