NeilsenRM(at)comcast.net Guest
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Posted: Fri Nov 23, 2007 9:00 am Post subject: Redrive VW Engine Details |
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I promise a few people that I would post this so. Here it is.....
Reduction Drive VW Engine Details
Custom Built 2180cc VW Engine: New engine case with shuffle pins, chromoly
studs, Scat chromoly 82 mm crank and H beam chromoly rods. Engle 140HE
hydraulic cam with Scat 1.25 rockers. 92mm Cima pistons with Total Seal 2nd
ring, 044 heads with 37.5mm and 42mm valves with single heavy duty valve
springs, 30mm oil pump, Compression ratio app 7.8 to 1, 12 lb. 8 dowel 6
volt flywheel. Great Plains Aircraft now sells nikasil cylinders, they
transfer 4 times the heat and weigh 10 lbs less.
Reduction Drive: Valley Engineering Series 3 Belt reduction drive 1.7 to 1
ratio.
Electrical system: Direct drive 20 amp alternator that is made for the Diehl
accessory case. Great Plains Aircraft carries these parts. I also use a 12
AH battery (TSC or Wall mart) it starts the engine down to about 50 degrees
then I have to give it some help with a charger.
Fuel System: The reduction drive mounts were the fuel pump would be so I
installed a primary electric pump and a backup electric pump in series. I
use a Facet low pressure pump as the first in line after the gascolator as
the back up pump and then mounted a high quality rotary pump that has a
built in pressure regulator as the primary pump. I also have a gascolator
with a Curtis drain valve mounted at the low point of the fuel system with
the drain valve sticking out the side of the fuselage. I also have an
automotive fuel filter mounted between the gas collator and the back up fuel
pump. The Primary pump can be purchased at California Import Parts.
Oil Cooler and Filter: 24 plate Mesa style oil cooler. Its mounted on the
back of the fuselage cage and it works almost too well. The kit is available
at most VW stores
Oil Filler: The reduction drive also covers the oil filler so I drilled a
valve cover for a Stemco plug. The plug is a truck brake drum dust cover
and can be purchased at a truck parts store.
Crank Case Breather: The reduction drive comes with a crank case breather
but the big VW engines need to breathe more to keep the engine from blowing
oil. I installed a three port dune buggy breather kit that has breather
ports in each valve cover and port for the reduction drive breather. Can be
purchased at most VW stores.
Ignition System: Compu-Fire Distributor less Electronic ignition system with
a VW 009 distributor as the timing source. Great Plains and most VW shops
carry it.
Tachometer: Originally I used a 4000 RPM electronic analog tachometer but
found that the operating range was just too close to the max on takeoff and
the pointer would just go to the peg. I now use a 3.5 inch digital from
Summit Racing.
Prop: PowerFin three blade 72 inch model F. I having it cut down to 71 inch
but PowerFin is recomending a 70 inch now.
Engine Mount Adapter: The Diehl accessory case has four mounting points but
the top two are cut off because they aren't used. Use the Diehl accessory
case with the 12 o'clock starter mount to clear the engine mount and exhaust
system. Great Plains Aircraft sells the Diehl case and a rear drive
adapter. The rear drive adapter is used for the other two mounting points,
but the alternator mount is cut off.
Exhaust: I purchased a dune buggy four into one system with J pipes as a
starting point. They are already configured for best performance so why re
invent anything. I cut it and tack welded it together to fit around
everything. I got a muffler shop to bend a single pipe to fit and tack
welded it to the three bolt muffler flange. I didn't use the muffler because
it is too heavy and it really isn't that noisy. I sent the exhaust system to
a welding shop to have it done right. Later I sent the system to a shop that
ceramic coated the system inside and out.
Carburetor: I installed a pair of 44mm Webers with aluminum manifolds. Now
the better choice is a Progressive Webber with a four pipe intake system.
With this intake system you will need a carburetor heat system. Great
Plaines Aircraft carries the carburetor.
Engine Oil Sump: I added a mini oil sump to lower the oil pickup point. I
was concerned about sucking air on high angles of attack like take off. This
is the only lowered sum that will fit using the Kolb/VW mount. I drilled and
tapped the mini sump for a oil quick drain valve, it is offset towards the
rear for engine mount clearance. Most VW shops carry the sump. Summit Racing
has the oil quick drain.
Flywheel & Starter: The Diehl accessory case will need a flywheel with a
ring gear for a 6 volt starter because the only starter that fits the Diehl
accessory case is a custom 12 volt starter with a 6 volt type gear. Also the
Diehl alternator requires a centering recess turned in the flywheel face and
5 bolt holes drilled and taped. Great Plains Aircraft carries these parts
already configured.
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