oil filters) are also good investments. Revmaster offers a big-
finned head. Most offer oil filter and cooler options.
A rookie engine builder needs to know that lengthening the
stroke can produce unexpectedly high compression. Cylinder
base shims and careful measurement cure this problem; longer
cylinders (available from Revmaster and Hummel) do the job
more elegantly. Nikasil cylinders are lighter than typical iron
cylinders and more expensive. Hummel produces its own long-body billet-cut Nikasil-plated cylinders.
Building your aero VW from an engine you already have in the
backyard may seem to be the cheap way to get started, but it
won’t be in the long run. And the frustration of making each
component airworthy will quickly overtake any dollars saved.
When you consider the price of a complete kit, with all new
parts (that will all fit together!) or a complete and test-run
engine, it’s almost silly to go shopping—unless, of course,
you’d like to build your “perfect” engine, using parts from several suppliers.
The complete AeroConversions 2180-cc kit sells for $6,495.
Its most-popular big options are the assembled crank/prop hub
assembly ($295) and aftermarket Nikasil cylinders ($500
option) that save 9 pounds compared to the standard iron cylinders. A kit from Great Plains (in 2180 cc or 2276 cc, including
magneto and electronic ignition) is about $6,500. Hummel’s
finished, test-run 2180, with similar ignition, retails for $5,850;
billet-cut, extended-length Nikasil cylinders reduce weight and
add $1,300. A Revmaster R-2200 (2180 cc) retails for $6,800.
The R-2300 (available springtime 2010) will cost $7, 100, and
R-2500 and R-3000 engines, with 90-mm strokes, are on the
way. All except the AeroConversions include stub exhausts.
Tim Kern is a private pilot and certified aviation manager as well as
an aviation writer and consultant based near Indianapolis. You can
find him online at www.TimKern.com.
To read a companion article on how to build your own
Volkswagen engine, see the February issue of Experimenter,
the electronic newsletter for homebuilders. Visit www.EAA.org/
For links to Revmaster, Great Plains Aircraft Supply, Hummel
Engines, and AeroConversions, visit www.SportAviation.org.
Sigtronics Combo Sets include a voice activated
intercom, two headsets, and a high quality bag
that will hold them all.
The Panel Mount Combo includes our
high performance Sport 200 intercom
and either two S- 20 articulating mic
boom or two S- 58 flex mic boom
The Portable Combo has our SPO-22N
high noise environment battery powered
intercom and the same option in
Hand-held radio for illustration only.
Not included with combo.
Military Headset Adapters
Changes the signal levels and impedances of military
headsets and helmets to work with general aviation
Available with U-174/U or General Aviation plugs.
Sigtronics products designed and manufactured in the U.S.A.