VwOilGallerySchematic

<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" ><B>Steve Kiblinger, .. Builder of a Milholland Better Half 2 cylinder VW and Legal Eagle Ultralight Airplane</B></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><B> </B><A HREF="brucesengine.htm" TARGET="_top" TITLE="BrucesEngine"><U><B> BrucesEngine</B></U></A></div> </td> </tr><tr> <td valign="top" width=200 BGCOLOR="#0000BF" TEXT="#F7F7FF"> <bR> </td> <td valign="top" height=380 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> <I>VwOilGallerySchematic</I></div> <DIV ALIGN="LEFT"></DIV> <div> <B><IMG SRC="25c30d60.jpg" border=0 width="560" height="470" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B>Gif file compliments of Danny Doolin...</B></div> <bR> <bR> <div> <B>The Better Half VW oil galleries need to be plugged in 4 places...</B></div> <bR> <div> <B>1) The rear main and cam gallery located in the right case half (from cockpit view)... Tap and put an Allen screw with Loctite in the main bearing web and the same for the cam bearing web... Be sure not to hit the main gallery with your rear main cover attachment screws - make no go marks on the case for later when you are tapping the four screws... </B></div> <bR> <div> <B>2) The gallery to the rear two valve lifter bores in right case half... If you have a scrap case knock the plug at the back of the case out for practice and use it again here after moving the good case plug out and then back in, with needle nose pliers and an </B><B><U>undersized</U></B><B> 1/4" x 6" brass punch, to the prop side gallery of the third lifter bore back of the prop... Reseal the gallery at the rear of the case by taping and use an Allen screw with Loctite...</B></div> <bR> <div> <B>3) The gallery to the rear two valve lifter bores in left case half... Use same gallery blocking procedure as in 2) above...</B></div> <bR> <DIV ALIGN="LEFT"></DIV> <div> <B>Failure to make these changes will result in low or NO oil pressure!...</B></div> <bR> <div> <B>There are other VW lubrication system assembly issues that are outlined in the </B><A HREF="http://www.greatplainsas.com/pg41.html" TARGET="_top" TITLE="http://www.greatplainsas.com/pg41.html"><U><B>Great Plains Type 1 assembly manual</B></U></A><B>...</B></div> <bR> <div> <B>Some builders recommend opening the valve covers just before the initial run up and dousing all moving parts with oil... We put 3 quarts of oil in the case and rolled the engine around the crank axis... We found and fixed leaks at the rear main bearing cover and both valve covers... Absolutely everything inside the engine is saturated with oil using this process...</B></div> <bR> <div> <B>We learned:</B></div> <bR> <div> <B>1) On the dual oil pressure relief valve case be sure to put the small plain valve and spring to the flywheel end... Reversal of the valves results in runaway oil pressure at 125 lbs +!... </B></div> <bR> <div> <B>2) Loctite 518 sealant is great for closing the case half's and the case side surface of the oil pump housing... Every place Permatex Aviation 3H sealant is called for expect a 50% chance of leaks!... We have replaced Permatex Aviation 3H with Permatex Blue Silicone sealant for a 100% first time success rate...</B></div> <bR> <div> <B>DO NOT use silicone sealant on the oil cooler bypass - the rubber may move thru the oil gallery!... We suggest tapping the gallery and plumbing with copper fittings which will also be lighter...</B></div> <bR> <div> <B>3) Our VW machinist advises that Permatex Red Silicon sealant is corrosive to aluminum and magnesium... We used it around the jug bases,  jug hole covers, the  rear main cover, the pushrod tube seals and the cylinder bolts that go thru the rocker boxes... We should have used it on the push rod hole plugs for the rear jugs - they are persistent weepers...</B></div> <bR> <div> <B>4) The valve covers must be fit close to the cylinder flanges - the full cover seat to flange surface is needed for successful sealing... We were not successful with the spliced original valve cover gaskets... If attempted try a glue at the splice - it's the only thing we didn't try... We cut full & accurate gaskets from 1/8" cork gasket stock... Further, bed these gaskets in a liberal coat of Permatex Red Silicon sealant on the cover and on the gasket surface that meets the cylinder flange... We have tried grease on the head side including the thick stuff from Aircraft Spruce & Specialities mentioned in the Experimenter and it always eventually leaks - USE RED SILICON SEALANT ON BOTH SIDES OF THE GASKET...</B></div> <bR> <bR> </td> </tr></table></body>