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  1. #1

    Default Schmleff's 2110cc Aircraft Engine (W/Picts)

    This engine was built to be as reliable as possible. Its hard to park on a cloud you know. The engine will cruise at about 3400rpm for normal flight and can wind to over 4000rpm for short periods. This engine should make my plane cruise at about 175mph and top out at about 185mph straight and level. I am building it to race in a 500 mile race from Dayton OH to Oshkosh WI and will also be used for general travel.

    Some background first.
    A VW engine in stock form is about 1600ccs. It has a bore of 88mm and a stroke of 69mm. There is a huge aftermarket for VW stuff and you can build an engine up to 2500ccs based off of the original design.

    Since the cylinders are removable themselves, increasing the bore up to 94mm is possible by machining the mating holes in the case and heads to fit. I opted for 90.5mm cylinder since they use thick sidewalls and resist warping the better.

    Strokes up to 86mm will fit in the case. You will usually have to do some clearancing of the case, rods, cam or pistons. I went with an 82mm stroke, since I wanted a special aircraft crank that was only made in 82mm.

    I ended up having to grind a little bit off of the rods, cam and case to keep things from hitting each other.

    I chose Scat forged rods with ARP head bolts and a Scat forged crank. The cam is an Engle 100, with 1.25:1 rockers giving me about .475 of lift at the valve. The duration is 234@.050. The cam is the limiting factor for high end power and was chosen to bring the torque curve down. The rods are as short as possible to also bring the powerband down.

    The heads have 40mm intake valves and 35.5mm exhaust valves and are CNC ported. The valve and head mods are not realized until the engine is wound over about 3500rpm.

    Total build cost with the $800 crank is about $2600. A normal crank would bring that down to about $2100.

    Dyno Workup:



    Rods and Crank



    Engine Case Half

    Jeff


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  2. #2

    Default

    Forged Rods and Pistons



    Cylinders (Jugs in the VW world)



    Clearancing Case for Big Crank



    Close up Jug



    Crank and Rods in Case W/ Clearance Grind on Cam

    Jeff


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  3. #3

    Default

    Checking Deck Height
    it had .010 to start off. I added a .090 shim under the jug to get the CR down to 8.1:1



    Case ready to be joined



    Schmear on case mating surface - red stuff is Redline lifter lube



    Case Mated



    Head studs installed

    Jeff


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  4. #4

    Default

    One head and two jugs on



    All four jugs with heads



    4-1 exhaust



    That is where she sits as of last night. I still need to add the oil pump, prop hub, and set the crank endplay. Updates to come.
    Jeff


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  5. #5

    Default

    very very cool!
    Boosted. Tuned. Ready.

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  6. #6

    Default

    I really, really, really like your workspace.

    The motor looks great. Can't wait to see it on the plane

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    Originally Posted by Colossus20v
    ^The years of ninja training helped...

  7. #7

    Default

    That is my electronics shop for my business. The carpet is called "Shazam"
    Jeff


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  8. #8
    CelicaTech Supporter TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light
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    Default

    Jesus man, how can that little amount of hp get that thing up to 175 mph?!

  9. #9

    Default

    casue it weighs 525 pounds
    Jeff


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  10. #10
    CelicaTech Supporter TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light TheNefariousOne is a glorious beacon of light
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    Default

    Ahh ok that would explain it. Are planes direct drive?

  11. #11

    Default

    this one is direct drive. you can see the prop hub in the last picture.
    Jeff


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  12. #12
    CelicaTech Supporter 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST has too many green lights. 90CelicaST's Avatar
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    Default

    Schmleff, did you ever finish this?

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    Originally Posted by Murgatroy
    I don't like people.

    I don't like going out.

    That is why my friends are all on the interwebz. That way when I don't feel like being sociable, I just close the window.

  13. #13

    Default

    yes
    Jeff


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  14. #14
    The Notorious P.I.G.
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    Default

    wow!

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    "Pain and despair, damage and beatings, they don't end the world. The world ends when you're dead. You've got more punishment in store. Until then, stand it like a man and give some back".

  15. #15

    Default

    Nice jugs!

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    Originally Posted by Murgatroy
    I was deaf, sore and majorly pissed off

  16. #16
    Trying To Learn Something New Each Day caneman is on a distinguished road caneman's Avatar
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    Default

    Hi Jeff,
    Your post brought back a lot of memories. I rebuilt my '70 VW Bus engine 3 times after sucking valves before I learned to ignore the VW factory manual and set the valves up loose (.006 all around I think, but its been about 35 years).
    I can still see all the engine parts in my mind. My wife used to lie under the bus and guide the driveshaft into the clutch as I pushed the engine in from the rear. All while it was 20 degrees F outside the garage. Ahh, what memories!
    Welcome to the asylum. The inmates are in charge here.
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  17. #17

    Default

    If you want me to add the picts and write up, let me know. This is the engine I flew in the race this past summer.
    Jeff


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