This manual details the assembly and work needed to adopt and install a Type 1 Volkswagen 1600 – 2300cc engine for light aircraft use in a plans built or kitplane aircraft.

Note: The typesetting of this book is sometimes difficult to read, but the complete and vast amount of information provided, makes the effort very worthwhile anybody considering this option for a plans or kit built aircraft

From the introduction
The VW engine has been used as a power plant in many application’s, besides automobiles. Some of these applications are: airboat s, dune buggies, water pumps, high volume smoke exhaust fans, air compressors, inboard, port able saw mills, tractor engines, wind machines, and of course, aircraft . In each case, the designer of the finished product looked at the VW engine as a base, upon which to build. Most successful engine conversions which have been built on the VW engine, are a series of compromises. The designer wanted to adapt t he engine to their particular need so the engine was modified to suit the requirements of that operating environment .

The VW engine as it is used in aircraft has a series of compromises that must be met. In almost all applications:

• The crankshaft must be modified to fit a prop hub.
• The cylinder bore and stroke may be too small to produce the power required.
• The case and heads must be machined for larger cylinders.
• The stock crankshaft in many cases does not have enough stroke to produce the required power. A longer stroke crankshaft requires careful attention to material selection.
• In addition, modifications to the case, rods, cam and pistons are required.