BrucesEngine

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=100 BGCOLOR="#CCCCFF" TEXT="#080000" bgproperties="fixed" background="05b00640egdysm.jpg"> <div> <FONT SIZE="2" COLOR="#000066" FACE="Arial" ><I><B>Steve Kiblinger, .. Builder of a Milholland Better Half 2 cylinder VW and Legal Eagle Ultralight Airplane</B></I></FONT><FONT SIZE="5" COLOR="#000099" FACE="Arial" ><B> </B></FONT><B>    |     </B><A HREF="index.htm" TARGET="_top" TITLE="Steve Kiblinger, .. Builder of a Milholl"><U><B>Home</B></U></A></div> <div> <A HREF="tools.htm" TARGET="_top" TITLE="Tools"><U>Tools</U></A>   |   <A HREF="empennage.htm" TARGET="_top" TITLE="Empennage"><U>Empennage</U></A>   |   <A HREF="fuselage.htm" TARGET="_top" TITLE="Fuselage"><U>Fuselage</U></A>   |   <A HREF="disk_brakes_.htm" TARGET="_top" TITLE="Disk Brakes?"><U>Disk Brakes?</U></A>   |   <A HREF="glue.htm" TARGET="_top" TITLE="Glue"><U>Glue</U></A>   |   <A HREF="wingspars.htm" TARGET="_top" TITLE="WingSpars"><U>WingSpars</U></A>   |   <A HREF="wings.htm" TARGET="_top" TITLE="Wings"><U>Wings</U></A>   |   <A HREF="ailerons.htm" TARGET="_top" TITLE="Ailerons"><U>Ailerons</U></A>   |   <A HREF="id31.htm" TARGET="_top" TITLE="WingsHow2"><U>WingsHow2</U></A>   |   <A HREF="id62.htm" TARGET="_top" TITLE="WingStruts"><U>WingStruts</U></A>   |   <A HREF="id40.htm" TARGET="_top" TITLE="Covering"><U>Covering</U></A>   |   <A HREF="whatdoesitweigh_.htm" TARGET="_top" TITLE="WhatDoesItWeigh?"><U>WhatDoesItWeigh?</U></A>   |   <A HREF="stanswood.htm" TARGET="_top" TITLE="StansWood"><U>StansWood</U></A>   |   <B>BrucesEngine</B>   |   <A HREF="gastank.htm" TARGET="_top" TITLE="GasTank"><U>GasTank</U></A>   |   <A HREF="suppliers.htm" TARGET="_top" TITLE="Suppliers"><U>Suppliers</U></A>   |   <A HREF="flying.htm" TARGET="_top" TITLE="Flying"><U>Flying</U></A>   |   <A HREF="eagler_s_nest_s.htm" TARGET="_top" TITLE="Eagler(s)Nests"><U>Eagler(s)Nest's</U></A>   |   <A HREF="id63.htm" TARGET="_top" TITLE="Builder(s)Gallery"><U>Builder(s)Gallery</U></A>   |   <A HREF="id70.htm" TARGET="_top" TITLE="LeonardThisWeek"><U>LeonardThisWeek</U></A>   |   <A HREF="contact_us.htm" TARGET="_top" TITLE="Contact Us"><U>Contact Us</U></A>   |   <A HREF="id82.htm" TARGET="_top" TITLE="John Bolding"><U>John Bolding</U></A></div> <div> </div> </td> </tr><tr> <td valign="top" width=200 BGCOLOR="#0099FF" TEXT="#F7F7FF"> <div> <B>Current work in progress.</B></div> <div> <B><IMG SRC="2e0a87e0.jpg" border=0 width="168" height="126" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B> <a href="HTMLobj-180/Bruc0902.jpg"><u>Click for large picture.</u> </a>  </B></div> <bR> <div> <B>Linda</B></div> <div> <B>The BetterHalf of Bruce</B></div> <bR> <div> <B> </B></div> <div> <B><IMG SRC="2e3a87e0.jpg" border=0 width="168" height="126" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B> <a href="HTMLobj-491/LindaB.jpg"><u>Click for large picture.</u> </a>  </B></div> <div> <B>Engine adaptation parts.</B></div> <div> <B><IMG SRC="2e6a87e0.jpg" border=0 width="168" height="126" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B> <a href="HTMLobj-492/vwparts.jpg"><u>Click for large picture.</u> </a>  </B></div> </td> <td valign="top" height=380 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> <I>BrucesEngine</I></div> <div> <A HREF="id74.htm" TARGET="_top" TITLE="CoolingTin"><U><B>CoolingTin</B></U></A></div> <div> <A HREF="id66.htm" TARGET="_top" TITLE="EngineAssembly"><U><B>EngineAssembly</B></U></A><B> <A NAME="engineassembly"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="1" ALIGN="bottom" WIDTH="1" HSPACE="0" VSPACE="0" ></A></B></div> <div> <A HREF="id61.htm" TARGET="_top" TITLE="LeburgDualEI"><U><B>LeburgDualEI</B></U></A><B> <A NAME="leburgdualei_1"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="1" ALIGN="bottom" WIDTH="1" HSPACE="0" VSPACE="0" ></A></B></div> <div> <A HREF="id59.htm" TARGET="_top" TITLE="MikuniCarb"><U><B>MikuniCarb</B></U></A></div> <div> <A HREF="id65.htm" TARGET="_top" TITLE="PropExtension"><U><B>PropExtension</B></U></A></div> <div> <A HREF="id67.htm" TARGET="_top" TITLE="Testing"><U><B>Testing</B></U></A></div> <div> <A HREF="id52.htm" TARGET="_top" TITLE="VwOilGallerySchematic"><U><B>VwOilGallerySchematic</B></U></A></div> <bR> <div> <A HREF="#wehavelearned" TITLE="BrucesEngine"><U><B>We have learned...</B></U></A></div> <bR> <div> Bruce Blauvelt is building the Better Half VW engine... We have most of the adaptation parts made and shown in the photo to the left... The <A HREF="http://www.demellocranks.com " TARGET="_top" TITLE="http://www.demellocranks.com "><U>DMS machine crankshaft</U></A> and <A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U>Milholland prop extension</U></A> are on hand with a balanced set of rods and jugs... The Milholland conversion is being followed with the exception of using, SCAT heads, hydraulic lifters, an oil filter and a <A HREF="http://www.leburg.freeserve.co.uk" TARGET="_top" TITLE="http://www.leburg.freeserve.co.uk"><U>Leburg Dual EI ignition</U></A> instead of the 009 VW distributor...</div> <bR> <div> <B>It's May 11, 2001 and Bruce has decided to retire in Colorado Springs, CO... Bruce is concentrating on preparing 2 houses for sale as a part of his retirement activity and I've picked up the engine building project... Bruce will be near his daughter in Colorado Springs... We will miss his good company and expertise...</B></div> <bR> <div> <B>We have a new case that is going to the machine shop Monday to be cut for 90.5mm Gene Berg cylinders... I've looked at </B><A HREF="http://www.betterhalfvw.com" TARGET="_top" TITLE="http://www.betterhalfvw.com"><U><B>Leonard's Head Conversion Video</B></U></A><B> and want to try the cut head adaptation... I bought a complete new 041 head and am taking it to the machine shop with the case to cut for the 90.5mm barrels and put a second 10mm plug opening between the push rods for the Leburg dual EI... There is a 45 day wait for a head from Great Plains at this time... The Mikuni flanges do not come standard on the Great Plains head so there is still alum welding to do and I personally just like the look of Leonard's finished product better...</B></div> <bR> <div> <B>It's June 7, 2001 and we had a disappointment with the 041 head... It was bought new and it turns out that the Brazilians use an 040 casting with big valves and change the casting model number from 040 to 041 with a punch... We set the head aside and went with a very high performance Mexican 043 head seen below... We decided to go with 94mm jugs because the 94's give trouble at the rear of the case that is unused by us and it seemed a shame to use great heads on little jugs - time will tell and it'll be reported in the Flying pages...</B></div> <bR> <bR> <DIV ALIGN="LEFT"></DIV> <div> <IMG SRC="2def4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <bR> <div> Bruce is examining the (DMS Crank) from <A HREF="http://www.demellocranks.com " TARGET="_top" TITLE="http://www.demellocranks.com "><U>DeMello Machine Shop</U></A> with jugs and rods showing in the background... Notice that DeMello provides the cap screw, washer and roll pin on the cut end of the crank if you specify "Better Half VW"... The counter weights are evident too... </div> <bR> <DIV ALIGN="LEFT"></DIV> <div> <I><B>LINKS that resonate for first time 1/2 VW engine builders...</B></I></div> <bR> <div> <A HREF="http://home.insightbb.com/~dannyjoe/" TARGET="_top" TITLE="http://home.insightbb.com/~dannyjoe/"><U><B>Danny Doolin on cutting the head...</B></U></A></div> <bR> <div> <A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U><B>Leonard's 1/2 VW cylinder head construction video...</B></U></A></div> <bR> <div> <A HREF="http://www.greatplainsas.com/pg41.html" TARGET="_top" TITLE="http://www.greatplainsas.com/pg41.html"><U><B>An assembly manual for VW Type 1 aircraft engines...</B></U></A></div> <bR> <div> <A HREF="http://eaa292.org/i-flyer.html" TARGET="_top" TITLE="http://eaa292.org/i-flyer.html"><U><B>EAA chapter 292 on a 1/2 VW mission...</B></U></A></div> <bR> <div> <B>Parts sources are posted on the "</B><A HREF="suppliers.htm" TARGET="_top" TITLE="Suppliers"><U><B>Suppliers</B></U></A><B>" page...</B></div> <div> ----------------------------------------------------------------------------------------------------------------</div> <bR> <div> <B>043 Mexican head CNC ported, Hemi'd, Dual spark plugs by </B><A HREF="http://www.thebugpatch.com" TARGET="_top" TITLE="http://www.thebugpatch.com"><U><B>TheBugPatch</B></U></A><B> <A NAME="thebugpatch"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="1" ALIGN="bottom" WIDTH="1" HSPACE="0" VSPACE="0" ></A></B></div> <bR> <div> <B><IMG SRC="219f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Using</B><A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U><B> </B></U></A><A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U><B>Leonard's 1/2 VW head modification video</B></U></A><B> you stake the rocker arm stands, split the head and then adapt rocker box pieces from a scrap head as seen below June 7, 2001... We practiced the split and intake pipe modification on the scrap head first...</B></div> <bR> <div> <B><IMG SRC="21bf4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B><IMG SRC="223f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B><IMG SRC="225f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B><IMG SRC="227f5780.jpg" border=0 width="501" height="376" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>The finished product</B></div> <bR> <div> <B>We used 1 3/8 inch 6061-T6 intake pipe for a better fit in the carb spigot and the CNC ported passages of the 043 heads... The welding was done by Don Bolton of </B><A HREF="http://www.thebugpatch.com" TARGET="_top" TITLE="http://www.thebugpatch.com"><U><B>TheBugPatch</B></U></A><B>... Allot of care was taken to not put flow restricters in the ports where the pipes meet the hole sawed casting... I went in there with a Dremel tool and smoothed everything tangent to the pipes and Don didn't break thru with blobs of weld - an easy thing to do...</B></div> <bR> <div> <B><IMG SRC="261f4a80.jpg" border=0 width="500" height="424" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B><IMG SRC="26214150.jpg" border=0 width="276" height="277" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>TIG is the way to go... See the difference from our MIG spot welds... May have to use some JB weld to smooth at the joint over the gasket surface...</B></div> <bR> <div> <B><IMG SRC="2bc75100.jpg" border=0 width="373" height="272" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Finished assemblies</B></div> <bR> <div> <B><IMG SRC="2bff4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <I><B>We have learned:</B></I><FONT SIZE="3" COLOR="#000000" FACE="Arial" > <A NAME="wehavelearned"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="1" ALIGN="bottom" WIDTH="1" HSPACE="0" VSPACE="0" ></A></FONT><I><B>The first step of building the 1/2 VW is to tear down a complete engine for parts and pay attention - take notes and pictures!!!</B></I></div> <bR> <div> <I><B>Good used parts are sometimes the best for our purposes - we had to go into new conversion procedures ($$$$) with after market valve rocker assemblies and the new Brazilian crankcase...</B></I></div> <bR> <div> <I><B>Another builder's expreience:</B></I></div> <div> <B>Subj: Engine building</B> </div> <div> Date: 09/02/2001 4:38:47 PM Pacific Daylight Time </div> <div> <I>From: dannyjoe@insightbb.com (Danny)</I></div> <div> <I>To: EaglersNests@cs.com</I></div> <bR> <div> Hello everyone.</div> <div> I spoke to Mr. Bob DeMello on the phone the other day, and had a nice chat about the 1/2 vw animal. I came away from the call realizing some big mistakes I have made in getting to the point of starting to put my motor together. If you are like me and starting from scratch on vw engines, and going to have to buy everything, do yourself a favor and call Bob. You must talk to <FONT SIZE="4" COLOR="#000000" FACE="Arial" ><A HREF="suppliers_crankshaft.htm" TARGET="_top" TITLE="Suppliers"><U><B><U>Bob</U></B></U></A></FONT> no one else will do. If he is not available excuse yourself politely, and call back later. I bought a new case, no good for our plans, the center main has been changed by the factory, Bob has good used cases and he understands what you are going to do with it. I bought everything from the car magazine vendors and everything I bought was wrong for our use. The cam gear, rocker shaft, the crank gears, the bearings, the cam, you name it, I bought it from the mag guys, and it was wrong in my case and Bob has it. He told me, once or twice a month, someone walks in with big wrinkles in their forehead, tore down about getting a 1/2 vw built, and Bob sends them away --grinning like possums-- with virtually everything they need to put one together, right down to the case nuts. Thought I would pass this information along, get the used German parts if you can!</div> <div> -Danny</div> <bR> <DIV ALIGN="LEFT"></DIV> <div> <A HREF="#engineassembly" TITLE="BrucesEngine"><U><B>TOP</B></U></A></div> </td> </tr></table></body>