How to build an airplane engine from garbage DIY
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- Опубликовано: 30 май 2019
- Beetle engine conversion to 2 cylinder boxer airplane engine, called half VW
4 stroke DiY engine, tecnical data: 1200 ccm (73 cui), 86 stroker crank, 94mm cylinders
43 HP at 2800 rpm (static) now with some fine tuning 47 HP
105 Kg (230 lbs) static thrust @ 31°C (~88 F)
47 kg (105 lbs) weight in order to fly, icluding all fluids, prop and exhaust.
2 Koso 28 mm motorcycle carburettor (better 24 to 26mm)
Engine in action first time:
• 1/2 VW DiY aircraft en...
smooth idle running with no vibration:
• 1/2 VW Aircraft engine...
Thrust test at 30 deg Celsius, idle at stable 700 rpm:
• 1/2 VW aircraft engine...
Build report on german forum:
www.motor-talk.de/forum/motor...
2 Koso 28 mm motorcycle carburettor (this is the upper limit and harder to tune and power increase is marginal, but this is what i had at home :) Better from 24 to 26 mm carb size, easy tune
105 Kg (230 lbs) static thrust
IF YOU DON'T LIKE THE MUSIC, PLEASE SHUT DOWN THE AUDIO :) 
Авто/Мото
![Sean Rii, Karyon, Sharzkii - Taungule [My Love] (Official Music Video)](http://i.ytimg.com/vi/eJoMuypbSzQ/mqdefault.jpg)
I flew one of those VWs for 15 years without an issue in a KR2 . It was a Steve Bennet conversion and was great.
Thank You for this comment.
Thats good for others to trust more to VW conversions
@@flyover1974 My VW was a 4cyl direct drive and it had no quirks .
Nice work, I am thinking of doing my own 2 cylinder VW mod (using plans) but seeing this helps me visualize what is entailed. Thanks for posting it!
Thank you! My working base was the plans from Milholland's Half VW but with some mods. One of them are the axial bearing. Someone made it behind the middle bearing on the end of the cut crank and the other way is in the prop hub side behind the first bearing.
A second minor mod but with big effect is the working on the cam followers from Bob Hoover. with this a lot more oil goes thru the cam rods and lubricate and cooling of rocker arms, valves and head is a lot improved. You need to google to hoover vw mods.
Cheers
A Brazilian friend had done this and actually he cut the case as well. Good job! Thanks for sharing to the community. 😀
Thank you very much :)
Do not cut the case because the saved weight get lost by the fat backplate and the needing oil cooler.
In my conversion the full case with aluminum covers at the unused cylinders dont need a oil cooler because of the big surface of the case.
I had problems to reach a good oil temperature and isolate the bottom of the case.
A static test with 30 degree celsius air temp and 15 minutes full power the oil temp was only 41 degree..
The only advantage of a cut case is if you have space problems and you need a more compact engine.
Cheers
@@flyover1974 Excellent information...and no music. Thank you.
this was one of the Best Detailed Videos I have ever seen, and in shortest time. Was GREAT, God Bless All
Thank You very much.
Probably the next video is an upgrade with Honda GX 190 head.
The Verner V3, V5 and V7 engine use this heads instead of cutted Beetle heads
I built one cut the crank , cam in half , plugged the back oil tally, added a thrust bearing mid crank journal, placed block off plates on two cylinders, retarded the cam to get , max horsepower at a lower RPM. It runs good on my Heath Super Parasol.
Thats some good work right there Well done
Thank You :)
buena amigo aproximado, cuanto pesa un motor Visa 2CV Citroen o Subaru sin avionizar. Gracias
Very impressed, you could have slowed down the video to give us more time to read your comments, and got rid of the crappy music , and played something calming. Thank you, wiz
Thank You.
I know about the poor video and music but it was some of my first videos...
Wiz kidd, you must be new to internet, digital age, and RUclips...Well, Imma genius and here to help you out...Okay, pay attention...There's "3 dots" at the top right corner of most RUclips vids...You touch the "3 dots"...You will see a selection called "playback speed "...I suggest you touch "25x" for your sake....That's the lowest speed ANY vid will play....Also, for any vid, you don't like the audio, reach and touch the "Audio Decrease " to whatever level you are comfortable with...To include....Silence or "0 %"....There you go...Any other problems, don't hesitate to ask...Imma genius...I'm here to help...Cheers 🍻!!!!...
Nice job and nice video.
Thank you very much :)
My Father did this in the late 60's for his Experimental Volksplane he built. He then built another for a KR2 he built.
Interesting concept but I think if you use a 3 cylinder Geo Metro engine they're really strong and dependable and I mean strong the only weakness in the Geo engine is the aluminum they use in the Pistons higher-quality pistons
Before i start to build this engine (in Europe) i was looking for other engines and some car engines was in my tighter choice. My favorite was the bmw smart engine.
But all the car engines need gear reducers and rise the weight and complicate the build.
The second reason was the cheap and worldwide spare part availability and the third reason was the already use in some homemade airplanes since this engine exists.
@@flyover1974 I don't know specs of it, but I LOVE the appearance of a 2CV motor. It's pretty, where the VW is boring, still...not the best criteria for a motor, but some people use them.
I have an N3 pup with the 1/2 VW motor.
I'm going to have to bring it home this weekend...bummer. But...such is life.
The advantage of the half VW is the weight. Probably the half or more of the geo metro engine. And the half VW is direct drive
@@flyover1974 The VW is direct drive and well proven and cheap .
Looove the title of this video
"Speed and power" -Jeremy clarkson
Thank you very much
@@flyover1974 np
Amazing. What a string of ingenious ideas and technical ability. I am not sure I would want to bet my life on it however.
@@burtvincent1278 thank you :)
That's the reason why i do 50 hours on ground in various power and weather conditions. Than i disassemble the engine and check or exzessive wearing. If i find nothing, the engine goes in my ultralight :)
Music is a personal taste...but there are technical questions.
How did you remove EVERY glassbead out of the oil-channels in the block? This are 90 degree angled channels, and blowing with air is not enough, there are corners where the beads stick to oil rests in this channel. When the oil comes hot they will come looseand can ruin the bearings.
Or do you change the bearings after 50 hours or so?
How many hours did you fly since june 2019 ?
this i a legitimate question and this problem made me a lot of headache. I need to open all oil gallery tab to clean all and i lost a few days to do this. i cleanded with gasoline and compressed air and brushes for pipe smokers. Then after first 30 seconds run i changed the oil and filter, after second run of 1 minute oil again and after third run of 5 minutes with fresh oil, i changed the second time the oil filter.
Then after some hours i opened the case and inspected the whole inside: there was some light visible wearing on the gears of cranck and cam but only cosmetic nature and no damage. The bearings was clean, probably because of the filtered oil before goes to the bearings.
This was 1 of 2 things i want never do on the next engine. Next time i close the block, close all openings and clean it with glassbead ONLY outside.
The 2° thing of wasted time was the head work. It was made to enlager the head volume but you can do this with simple spacers under the cylinder foot.
I did not fly yet because the ground running time of 50 hous is not finish and i dont had time in the last year
@@flyover1974 You identified the problem, it is OK then. Remind that it is aviation , you can drop dead in every flight.
@@louisvanrijn3964 You are right and for this reason i do the ground testing for 50 hours. Than disassembling the motor again and check accurate if there are some abnormal wearing. If not, the engine is ready to use for next 25 hours in a ultralight plane before you disasembling again. If the wearing is in normal limits, go to 50 hours of check.
If you want to get more save, put it in a motorized hang glider, so if the engine drops, you can glide
You are not a average gyi you have a machining tools. But nice that you mentioned "Even with those Chevy rods" maybe I must get a pair of those too.
Im sure that im not an average guy but even im not a professional. I dont have more machine tools than a average self made man. Sure, if you never work often in your garage and your tools need not more space than a toolbox and your skills are not more than cut a cable or fasten a loose screw, this is not a project for you ;) but im sure you know that.
About the chevy rods, you need the specific crankshaft with smaller journeys, VW use 55 mm and chevy rods use 2 inch (50.8mm). When you want to use the maximum stroke crank (86mm) without larger modification of the motor block, you need the smaller journeys.
If you use the 82mm stroke, you can use the original VW rods.
All this stuff i read in german beetle forum and in the legal eagle forum: www.eaglersnest.com/forum/
Did you use any engine plans to build this? I am interested on how you balanced the counterweighted crankshaft.
Yes i used different plans. If you google for half vw engine, you find more plans. But mostly i follow the "better half vw engine" plans from Leonard Milholland.
He use a extra additional weight to counterweight the crank and it works very fine. Look at my other videos where the engine run on the stand without any fixes and it stays very stable and very less vibes
@@flyover1974 Thank you for the reply! That is why I was asking because I have Leonard's plans but his crank doesn't use the last throw and instead uses a plate you bolt on. But yours shows you're using that throw at 4:22 and I guess that bearing is a split bearing. I can't find any plans that shows you how to do that...
@@backyardgarage912 if you mean the last counterweight, it is the half of the 3th piston journal. But this alone isn't enough, you need to counterweigh the prop hub too. Hope you undersand what i mean.
The pull bearing for the prop traction is realized at the inside of the first cranck bearing between the first counterweight flange and the bearing.
What was the original power and displacement? You started with the oldest Type 1??
original from 79 if i remember it correct and was a 4 cyl boxer with 1300 cc displacement, now is 2 cyl boxer with 1200 cc
Nice!
Qual o valor a potência o peso desse motor? abraços
45 cavalos y 47 kg
Way too much music distraction, and hard to read with non contrasting background.
Thank you for advertising. I' m sorry about this. It's my first foto show...maybe try the mute taste and pause to better read ;)
How much for complet convertion this engine 43 hp and do install tree palm propeller with starter ???
Hi, around 1200 Euro for conversion parts if you do by yourself. Starter is not necessary, handstart is very easy but you can mount something if you want. 3 blade prop is only necessary for stronger engines and is more weight and less performance than 2 blade
I'm not an aviator but am currently about to completely rebuild my Type 1 VW 1776cc air cooled lump. The question which keeps ringing in my ears is why didn't you just stick with a 4 cylinder lump? There wouldn't be that much difference in weight, you'd have more power, and also more likelihood of the engine continuing to fire on a couple of cylinders if 1 or 2 of them decided that they fancied a nap!! ... ?
Hi, in aviation every pund...or better every ounce of less weight is important. Example: i want to put a engine in an single seater ultralight plane with a maximum take off weight of 600 pounds (272kg). There is the complete VW 4 cylinder oversize in power and weight.
My engines weight including prop and liquids is about 47 kg (103 pound) with a power of 45 hp on 3200 rpm.
The engine power to weight ratio is super and more than enough for the single seater plane i told.
And engies for aviation are build with target of maximum reliability instead of maximum power. For that reason my engine has only a compression ratio of 8,2 : 1 ...this help a lot to not stress the moved parts but you loose something about 10-20% power
Cheers
@@flyover1974 A 4 cyl direct drive with exhaust, carb and single mag is 160 pounds .
Quantos cavalos de potência e seu peso e como adquirir o mesmo?
45 cavalos, 47 kg, auto-fabricado não está à venda
Where did you move the thrust bearing?
I move the thrust bearing to the front (prop side), i used the original hardened spacers that normally are on the flywheel side but it needs to enlarge the inner diameter a little bit. I did this with a dremel while the spacers turn in the lathe.
Would it not have been easier to use a 2 cylinder Citroën 2CV engine (aircooled, 602cc, 30 hp)?
You are not the first guy asking me these question. The Citroen is way smaller, only 600 cc and the whole engine is designed for this size.
It's a good engine but too small and weak for stronger upgrades.
And the 30 hp is maximum, for flight purposes is not good using a car engine at 90-100% of power. And to use this power you need a gear box instead of direct drive of VW
@flyover1974 Ok, thanks for your reply. Although a reliable 45 hp can be had from the 2cv engine with some carburator work and a 'big bore' kit to 650cc.
@@flyingdd but you need in any case a transmission and this is more weight and more pieces that can fail. And the significant higher rpm is not a tipical sign for reliability 😉
And 45 hp out of 600 to 800cc is not possible with low compression and low rpm, but this are the real mix for a reliabily engine
@flyover1974 That makes sense. I did not take the low compression and rpm requirements into account.
Well,that taught me all I need to know about building engines.
Nice to know this video could help you
@@flyover1974.how much trouble would I get in if I put a 400 hp VW engine in a Hummel Cruzer ultra light?
@@gerald4027 i am open mind and i never say no but some things are not possible...
Whitch kind of VW engine you mean? I don't think it is a old aircooled boxer because it is not possible to get 400 hp from this engine and if it's possible than the engine is not enough reliable for flight use because it is made for maximum power and not for maximum reliability.
Anyway a 400 hp engine in a single seater ultralight is crazy oversized and for the ultralight you tell is probably never possible because the whole plane is not designed for that much power, neither the structure nor the airfoil.
And a 400hp engine probably weight minimum 3 times more than the 2 cylinder boxer with 45 hp.
Only for this reason you need to make mayor changes in the lenght of the structure to get the right balance and so you change the flight properties to unknown because nobody did that before...
My opinion: no way... forget it
@@flyover1974.my brother owned a sand drag rail dune buggy and it had a VW engine dynoed at 550 hp. Hilborn mechanical fuel injected, t4 turbo,real aggressive high rpm cam and nitro methane. It would rev to about 10500 rpms.engine built in California.
I was thinking 400 hp,but then I read what you said.Would a 2 cylinder built for torque work good in a plane such as a Hummel or a Facet Opal flying wing?
@@gerald4027 Do you think a engine whith original 45 hp, pumped up to 400 and more, is reliable to work hour after hour at 70% and more of his max. power?
Why airplane enines normally are the double or triple displacement of a car engine with the same power?
Because they need to be RELIABLE.
Never a vw beetle engine with 400+ hp is reliable to work in a airplane. The airplane engine never can quit in air because this is probably your end.
In a car if the engine quit, you drive to the boarder and stop there.
For your question:
A single seater ultralight plane work good whith 35 to 60 hp.
Important is not max power but only reliability and this is reached normally if engibe is build as simple as possible with low compression ratio and low revs
Can i ask a silly question ? Why go to all that trouble , why not use the whole 4 cyl engine ? just asking 😁😁👍👍
Bcause for my specific use a 4 cyl is oversize in weight and power
flyover1974 thanks just wondered 😁 good engineering dude anyway 👍👍
Nice project! Which music did you use?
Thank you.
I dont remember exactly the title and interpret but if you search here for free maker music, you find a lot and probably this one too because its popular on youtube.
But maybe its better to search different one because you are the first one of 100 people who like it ;)
Cheers
i changed the music because there was a problem with rights but i was meaning the music was free...
@@flyover1974 ooh that sucks.... But, if the contact you, than you know have the artist and titel of the song you used?! Im stil looking for it
@@geschut you mean this one now? Because i changed recently due rights problems
@@flyover1974 no, the one before that you had to chance :-)
What's the point of a half of a VW
A whole VW engine is big and heavy and for a single seater ultralight plane oversized.
The half one is lightweight with a good power to weight ratio. Mine weight 105 lbs in order to fly included prop, mount and all needed liquids
cool
thanks :-)
Airplane engine and garbage in the same sentence is kinda scary
why ? It was garbage at the beginning and transformed in a good quality product.
That need the single pieces of good quality and the original 48 year old Volkswagen pieces are som of the best quality products. Aftermarket mostly can not reach the original quality
Not sure I understand why you would make a 2 cylinder VW engine.... Why not just us a BMW R series air head?
Need a reduction gear, heavier, too high rpm to reach the power, more mecanical pieces that can fail....and a lot more reasons. This question is made often in this thread
You should never glass bead blast the inside of any engine
Thats right :) but at the time i start to build the engine i didn' t know that and then i waste a days of cleaning time :(
Next time i bold it together, close all open holes and sand blast it ONLY outside.
cheers
@@flyover1974 :: Strange talk to me, but as I watched the pictures I understood a little more about what it takes to convert a VW engine to an airplane engine. My uncle did that in th 1905'ies when I was a kid, and showed me one of his creations in 1970. The sound of that engine in a little Jurca I think it was -- fabulous!
@@dibaldgyfm9933 this conversion was a little more complicated than a simple VW conversion made mostly in 50's to 80's. There the people use a standard 4 cylinder VW, rebuild it, replacing weared pieces, add a dual or single carburettor and thats it.
The hardest thing to do was to spindle the bore for the prop hub and this normally was doing by a professional motor garage.
But this engines are reliable and cheap not only in the 50's.
A lot of people use it right now.
...and yes! The sound of this engine is awesome :)
@@flyover1974 yes you can alloy castings are then dipped in hrdrofrlouric acid which dissolves the beads
Why not just use all 4 cylinders? Would be a lot easier smoother and more power . Your finished product is not that much smaller !
Because is overpowered and too heavy for a single seater ultralight plane
"Cutted" parts ??
Soory for my bad englisch...i mean the crank is cut in 2 parts, even the cylinder head. For this it is necessary because the cylinders on the original VW are 4 and now there are only 2 remaining, but the cylinder head is 1 piece for 2 cylinders so it need to be cut in halve and rebuild partial.
yes. You need only the half crankshaft on a "half VW" because you spare 2 cylinders of 4 ;-)
most people can barely tie their shoes... wow.
Thank you. It was a 3 month project, not fulltime but every day 2-3 hours.
I like to make tecnical things and because i have the pilot license, this was the right project for me :)
Why not start with a BMW boxer Bike engine?
After all it was designed by Sopwith before WWI when it was called the ABC engine…
We had the thema 2 years ago, this engine need a reduction gear because the power is reached at higher rpm. This leads in unreliable engine for longer flights, more weight, more mecanical pieces in motion that can fail and more maintenance. The reason because most airplane engine are direct driven is exactly this. And last, a bmw boxer engine is more expansive
I'm sure you meant "an" airplane engine.
exactly...i change it as soon as possible
This is a music video. I thought this was about engine rebuilding.
You are free to think what you want ;)
Seems like alot of work for nothing rather have all 4cyl
I learned to buy a Verner in lieu of modifying a VW
If you have enough cash to buy a 6.000 to 10.000 Euro Engine you can do that. If you want flying with small budget, you need to go this way 😉
If you would ditch the music and offer voice over of what we are seeing, and what you are doing you might exceed 700 views, no hate just a thought 🤷🏼
Probably you are right but im better with my hands than with my voice 😉
Dear RUclipsrs we hate music.
No problem, for people like you, someone invented the mute key 😉
@@flyover1974 just cause some youtube guru told you that you need to use music in your videos does not mean you should.
You are free to exprime your opinion but is your personal and subjective opinion. Most of the people around the world like music and me too. So...back to the beginning, turn it off if you don't like it 😉 and enjoy the mute video 😊. And...be sure, i never asked some guru for anything because i like it to do my way.
@@flyover1974 lots of oeople besides me don't like it.
@@allywilkeforsenate That's ok. Everyone can do how it want and i want it with music ;)
Had to mute it to watch it.
U are not the first ;)
Music is not for everyone
I wouldn't trust that
No problem :) i do...
DIY ? OK, First buy a TIG welder $6000, then a CNC mill $50,000 (guess, but for sure not cheap) then Trade School to learn how to use this stuff $10,000 (another guess, but certainly not free) now buy a few VW core engines because you're going to screw some up before you get it right. Last but not least, check that life insurance is paid up before first flight.
YES, DIY ! The Tig welding was outsourced and cost me a sixpack ;) Nonetheless i own one and cost new 700 bucks... for sure is not for every day working but for home working is good enough.
The cnc mill is selfmade and cost me around 600 bucks (see my other videos), anyway you dont need a cnc mill because the head work is not necessary because you can also put some spacers under the cylinder to get lower compression. Next time i do this and spare a lot of unnecessary work.
I build the cnc by myself and how to use, i learned by myself. Its not that hard ;-)
And for the rest, search here on youtube, you will find a lot of vw engines running on airplanes exactly because they are above average strong and reliable.
If you are a fearful person, just stay at home and do nothing...
@@flyover1974 Thank you for taking the time to write a reply to my comment which was intended to be on the humorous side with a certain amount of truth. I have a 4000' shop with a mill, lathe, MIG, TIG, Shear, Brake, 12 and 50 ton presses and every hand tool you can imagine, none from Harbor Freight. I call it a "Hobby Job Shop", I work on old cars and do some light fabrication for myself and friends. What I'm trying to say is that I'm pretty handy, BUT WOULD NEVER ATTEMPT TO DO WHAT YOU SHOW IN YOUR VIDEO. You're a very skilled designer and fabricator. I believe you've been at this sort of thing for years; definitely not your first rodeo. The average person would not get to first base trying what you profess to be easy.
@@badron9245 thank you :)
i work for hobby with things like this and your "shop" is my dream :)
normal men have garage tig welder, and diy cnc build under 1000 $ ,i has build 200 cnc machine hobby users and have totally cheap if looking used big steppermotors craveyard and lot parts can salvage many place. cheapen TIG welder who can use normal hard work ewery wekend hobby builder, cost 300$ NOT 6000$ i not has newer see 6000$ tig, maybe some big pro manufactory automatric TIG but not newer any normal hobby tig less than 200A current no need more. my first TIG has MMA,TIG,plasma cutter 3 to 1 machine cost 340$ and second has better TIG cost less than 300$ but lot better pro model. all new. not used, used TIG can buy 200-500$ million shop. learn how use no cost anythink you can learn in home weekend easy. how welding no need learn lot, cnc can use learn in home and internet little and garage test how work easy little job and normal men can use. idiot need go to school ofcourse.
@@mattivirta Speaking of going to school............
.......
При всем уважении к "золотым рукам" автора..- этой глупости понять не удаётся! Угробить двигатель ради чего? Был получен прирост удельной мощности на 1 кг.веса?!..
sorry, i do not speak this language. Please english, german or italian. thank you
With all do respect - a 48 yr old motor, your first 1/2 VW conversion (I assume), and you are sitting behind it flying your UltraLight. You are literally betting your life on that engine. Doesn't make sense to me.
This is only the engine block and the camshaft with 48 year, and both are checked if they are good. The old original VW pieces often are much better then the newer ones.
And about the reliability, the engine remain on ground for 50 hour running test. Then disassembling and checked for excessive wearing. If all is good can mount on airplane. This is not the first VW conversion for airplanes and most of them are very reliable because the engine itself is known as a reliable engine
The engine is very safe. as long as built properly.
WTF..LOOSE the music
WTF..TAKE the MUTE buttton, my channel - my music.
Whats wrong with you?
I had to stop because of that GAY music!
This is the most common official music used in youtube build and make videos.
If you don't like it use your mute function because this video is made for eyes and not for ears
@@flyover1974 Why did you add music? If we mute the sound we might miss if you say something. This is a problem w/ some videos. The music is terrible.
@@alext8828 it' s my first video and the next one i try to find some better music
@@flyover1974 Why use music at all? We all hate it. Is RUclips telling you to use music?
@@alext8828 I said, it's my first video like this and watching other make videos...everywhere are the same 5 music....so i used one of them and the second reason was because there are no copyrights