We will be cleaning out the garage and attic to find those items we

B E E T L E
F L Y E R
•
W I N T E R
2 0 1 0
Great Plains Aircraft
Supply Co., Inc.
Happy
Holidays!
Hoping that 2010 was a
great year for each of you!
And we hope that your
airplanes are getting close
to flight!
We thank each of you for
being our customers and
another successful year at
Great Plains!
Hope that 2011 is full of
great flying days!
This next year, will be our
29th year (that’s very hard
to believe) of selling VW
conversions and parts for
Sport Aircraft. We have
exhibited at Sun and Fun
and Oshkosh, (now Air
Venture) since 1984. Plus
we have been conducting
many
forums
and
workshops at both of these
air shows.
What’s in the Beetle Flyer?
Beetle Flyer Sale!
•
•
•
•
•
New 12” x 4” x 5” Tire
Ethanol in Fuel
Sun & Fun 2011
Oil Choice
Fuel Injection & MORE!
NEW!
35 Amp,
3 Phase Alternator!
The new 35 Amp 3 phase alternator brings many benefits to our
VW conversions. First, all the amps are in by 1500 rpm. The
magnet ring has a .006” stainless steel ring pressed around the
magnets so they can never come loose and wedge between
another magnet and the stator. And the best benefit is that 3
phase does not produce any electrical noise for your radio! This
fact is not so important for metal or steel tube airframes that have
a good ground, i.e., the whole airframe. But for wood and plastic
aircraft it can make a tremendous difference in noise, especially if
you using one of the less expensive aircraft radios.
To answer a few questions:
Will my older Diehl Case accept the new 35 amp 3 phase alternator?
No, it won’t. The magnet ring on the 3 phase alternator is about
3/8” deeper that the old 20 and 22 amp alternators. The Master
Pattern had to be modified to accept the new alternator.
Will I still be able to get parts for the 22 amp alternator? Yes, we kept
back a good supply of stators, regulators/rectifiers and have an
adequate supply of magnet rings. The only parts we have really
replaced to date are a few stators and the regulator
rectifiers. Keeping the regulator/rectifier cool and making sure
they have a good ground is the secret to keeping them healthy.
Is there a weight difference between the new 35 amp 3 phase alternator
and the old 22 amp single phase alternator? Yes, the new alternator
with regulator weighs about 3 pounds more.
BEETLE FLYER 2010
WINTER 2010
NEW! 12” x 4” x 5”
Slick Tire & Tube!
Many years ago we had a great 12 x 4 x 5 - 4 ply slick tire and
tube available. Dimensionally it is only 1” narrower than a
standard aircraft 500 x 5 tire. It disappeared many years ago.
While at the Small Engine Trade Show in Louisville, KY, this
fall, we found our old 12 x 4 x 5 4 ply slick tire to be available
once again. A pair of them, 2 tires and 2 tubes runs $74.95 plus
shipping.
Ethanol in Fuel
We may be finding that the ethanol in the fuel we use in
our aircraft may not be the best thing to burn in our VW
conversions. We had two cases this year of stuck valves
- in almost brand new engines! Both engines were using
ethanol. The valves stuck as early as 2 hours on one
engine and at about 5 hours of operation on the other.
While it is not by any means a scientific test, just be
overly cautious if using ethanol laced auto fuel. This
might be a good discussion topic on some of the VW yahoo sites
and at Sonerai.net to see if any other VW flyers that are using ethanol and what, if any issues they have
had. I would be especially cautious if using a POSA type carburetor due to the increased possibility of
vapor lock.
Sun & Fun 2011!
Sun and Fun is earlier this year (March 29 to April 3)! We will
again host our “Build a VW Engine” in the Engine workshop
area. This is a four day workshop that only takes 1 to 2 hours
per day - starting at 11:00 A.M.
Day 1 is VW Aviation History, engine selection, and what parts
to use and not to use.
Day 2 is assembly of the short block.
Day 3 is completing the engine assembly and adding the
accessories.
Day 4 is fuel, carbs, and cooling.
No need to sign up, just show up. We have ran this program at
Sun and Fun for about the last 10 years and at Oshkosh for the
last 5 years (or so) and have had literally 100’s of
graduates. Well, no one got a diploma, actually… But, we think
it has made flying a VW safer at any rate!
2
BEETLE FLYER 2010
WINTER 2010
Easy Eagle I takes Flight in Nebraska!
Back in 2005 I started building an Easy Eagle I.
Unfortunately I would rather fly than build and
when my bride said – If you don’t want to finish
it – why don’t you sell it? That is when the
project ended up with Kevin Wilkinson. Kevin
took the wings without fabric and the fuselage
on gear home to Grand Island, NE to finish.
He finished it beautifully!
The Easy Eagle I took flight this summer! He
said that it flew wonderfully. He truly enjoys
flying it!
GARAGE SALE RETURNS!
As soon as the Christmas holiday is past…. We will be cleaning out the garage and
attic to find those items we no longer need. Then pictures will be taken and uploaded
to our web site. This is your warning!
Last of the Sonerai
Newsletters…
2010 marked the end of the Sonerai
Newsletter written by Fred Keip. We
celebrated his many years of service to
the Sonerai Builders at Oshkosh Air Venture this year. Fred isn’t leaving the Sonerai
builders – he can be found at Sonerai.net! Thank you Fred!
3
BEETLE FLYER 2010
WINTER 2010
Fuel Injection for VW’s?
We get asked frequently about fuel injection for
VW engines and why don’t we have it
available. After going through the exercise
ourselves and with a few customers both in the
states and abroad that have it on their VW
powered aircraft the simple answer is it’s “simply
too expensive”!
One of the easiest systems to use is a system
made by SDS out of Canada (their system is
installed on the engine to the right). The parts
for the system with the programmer runs about
$1300.00. Next, add a high pressure fuel pump (or two) at $125
each. Now we have to add a throttle body. You can find a used one off of E-bay for an
old 1.9L Ford for about $30, but if you want a new one, it is $400. Injectors - new ones run $60ish each
x 4. Add a fuel pressure regulator at $85 to $150. Intake manifold (custom built) is about $400, with
bungs for the injectors. And let’s not forget the hoses and fittings!
Then of course we need a throttle position sender, air temp sender, manifold pressure sender, CHT
sender, rpm sensor, etc… (some of these item are in the SDS kit). In reality by the time you add up all the
expenses of a fuel injection system for the VW and add some profit, the system is going to sell within a
couple hundred dollars of $3000! Not real feasible is it? Especially for an engine that sells for $6000 to
$7000 dollars is it? Who is going to spend half the price of an engine, for a fuel delivery system? Not
many!
Oil for your VW?
Everyone has a different opinion on what oil to use and which weight. The
VW service manual says ‘30 weight oil’. That is what I have always used and
is what we recommend for our engines. Remember the oil has to go through
the small opening on the lifter, up the small hole on both ends of the pushrod
tube, through the rocker arm and down the thread of the adjusting screw to
lubricate the valve train. A higher viscosity oil, takes longer to warm up, is
harder to get pushed through the narrow opening in the lifter, pushrod and
rocker arm. Camshaft - lifter and valve train failure can all be attributed to
thick oil. A 60 weight oil for example is 100% thicker that a 30 weight oil, at
least by my math.
Oil has a number of jobs to do in an engine, not just lubricate. The oil’s
primary other job of course is to collect heat, transport it to the oil cooler and
shed the heat. A high viscosity oil will produce a higher oil pressure, but at the
expense of a higher oil temperature.
The VW service manual lists the following for a minimum oil pressure: “Oil
pressure for SAE 30 only” at an oil temperature of 158ºF at 2500 rpm
results in 28 psi for a Type 1 engine. It does not list a max at any other rpm,
nor does it list a minimum at idle.
4
BEETLE FLYER 2010
WINTER 2010
Beetle Flyer Special! Sale begins 12/24/10 to 1/17/11
Order at 402 493 6507, by fax at 402 493 3846, or online at www.gpasc.com
No substitutions or changes to the packages. Shipping/freight is NOT included in the price.
Order online and we will adjust your order to reflect the Beetle Flyer price!
1. Sonerai Spar, ailerons and Spar Cap Kit includes 2 each of the main and rear spars, 2 each
of pre-formed ailerons and the spar cap kit. All
can ship in one box via UPS oversized. This kit
is $900.85 with the crate cost, BF Priced at
$799.95.
10. Sonerai intake manifold, new 2122 carb and
Sonerai Fuel Proof hose kit - Same as the other
two packages but for VW based sleighs with
engines from 2180 to 2276cc. Kit is $692.99, BF
priced at $623.69.
2. Sonerai II or IIS Cowling – We have an
overstock. Takes up as much room as Santa's
Sleigh. Move them out for $378 (includes box
charge). Cannot ship via UPS.
11. Tool kit – The list of tools is found in our catalog.
Took kit is $143.50, BF priced at $121.95.
12. Battery, CD solenoid, master disconnect switch
and mag switch - What did you think light up
the Sleigh? Battery is a 12VDC Glass matt with
240 initial CCA and only weighs in about 10
lbs. CD Solenoid is the master electrical switch
for the sleigh and of the course the mag switch
can turn the lights on. In the event something
goes terribly wrong on his trip, the master
disconnect switch can turn off everything
electrical. Kit is $171.70, BF priced at $154.50.
3. Sonerai II or IIS Canopy. Santa used this one
too – it has great vision. Has Santa ever
delivered a wrong package? $295 Boxed. Must
be shipped by UPS oversize.
4. Sonerai/CX 4 Gear kit with gear, pair of ¾” prewelded axles with axle nuts, 2 each 5” wheels, 2
each 12 x 4 x 5 slick tires and tubes, hydraulic
brake kit and 2 each heel toe master cylinders and
2 each hydraulic tube kits. All this total up to
$1195.50. BF Sale priced at $1075.95.
13. 10” or 12” spinner kit – Includes spinner, front
and back plates. In Aluminum Only. Take 10%
off kit. 10” BF $87.90 and 12” BF $101.50.
5. Sonerai tailwheel caster with 4” wheel and
tailwheel spring – The kit is priced at $198.85.
BF Priced at $169.95.
14. VDO instrument package. Includes oil pressure,
sender, oil temperature, sender, cylinder head
temperature with sender, voltmeter, ammeter,
hour meter. All instruments are 2 1/16”. VDO
package is $272.77, BF priced at $245.50.
6. Sonerai large tailwheel caster with 5” or 6” wheel
and tailwheel spring – Take 10% off the three
items. 5” BF $177.50 and 6” BF $197.95.
7. U-build exhaust kit in 1.5”, 1.375” or 1.250” tube
sizes. – Priced at $110.95, but BF Priced at
$95.00.
15. Book set – all about motors and like
stuff. Includes Assembly Manual & DVD set,
How to Rebuild, Baffle Manual and How to
Hotrod. All for $76.45 – savings of $9.00.
8. Sonerai intake manifold, 1617 carb with Sonerai
Fuel Proof hose kit. This works well with VW
based sleighs with wings and a engine that is
1600 to 1700cc. Kit is $622.70, BF priced at
$560.43.
16. Sealants & lubricants. All the sealants and
lubricates needed for engine assembly. Includes:
DieElectric, Assembly Lube, 518, Hi-Temp, Blue
Threadlocker and PST. Priced at $52.24, BF
priced at $47.00.
9. Sonerai intake manifold, 1819 carb with Sonerai
Fuel Proof hose kit - Same as above but for VW
bases sleighs with engines from 1800 to 1915cc.
Kit is $663.22, BF priced at $596.89.
17. CX4 rivet kit- The same one that holds the sleigh
together.
Priced at $332.66, BF priced at
$282.75.
18. Shrink Fit Prop Hub kit – Priced at $159.95 and
BF Sale is $135.95!.
5
GREAT PLAINS • BEETLE FLYER
WINTER 2010
Extended Storage?
If you have a brand new engine that’s never been run
or one on your aircraft that just sits for the winter,
you may consider prepping your engine for
storage. Here are several easy things you can do
that will keep your engine healthy.
2.
3.
4.
5.
6.
7.
8.
1. For an installed, running engine, consider
fogging it. Simply, use a spray bottle of
lightweight oil and spray the carburetor with the
engine running at about 1200 rpm and choke the engine down so it
quits. Yes, the engine should be at operating temps and if needed, remove the prop to do this.
For an non-installed, non-running engine - remove the top plugs and using a syringe, put an ounce or
2 of oil in the cylinder. I use a small tube on the end so I can move it around a little when pushing the
oil out of the syringe. Do this to each cylinder and re-install the plugs. Do not turn the engine over
again!
Remove the valve covers and take the rocker arms off. This closes any valves that may be open and
keeps the moisture out of the cylinder. Stops our good friend “Rusty” from working. Keeps him on
unemployment!
Cover the carburetor inlet up so air cannot enter.
Cover the exhaust outlet up so air cannot enter.
If you cylinders are not painted, spray a light coat of WD-40 on them to prevent winter rust. But
don’t get carried away.
Change the oil! Don’t let used oil sit in you engine all winter long. You may consider adding the 4th
quart so oil is up over the camshaft and lifter. If you have a tail dragger, raising the tail so the
aircraft/engine are level for the winter. This covers more internal engine parts.
If allowed by your Airport Authority, you may install a 40W light bulb or two in the cowling, under
EGT and CHT Confusion?
There is lots of confusion about EGT and CHT. I would advise all to go to these three web pages and
read the facts about both:
http://www.avweb.com/news/maint/egt_and_cht_interpretation_198791-1.html
http://www.sportaviationonline.org/sportaviation/201009/?pg=95#pg95
http://www.foxvalleykart.com/gauges.html
Understanding egt/cht will make your flying a lot more comfortable if you aren’t worrying about your
EGT in particular. Both of these articles in that link are very good!
And on the CHT side… I would only add that if you take your CHT reading on a VW under the plug…
which is the hottest spot, the max is usually about 450ºF. If you are taking the reading from under a
cylinder head stud washer, behind the intake manifold, the maximum CHT should be about 325ºF.