Here is a sample of the mail:
On ‘Getting Started’, Zenith 750 builder Blaine Schwartz writes:
“William, What a great idea for planning the build and keeping track of progress. I volunteer to create a basic excel spreadsheet that you can make available for those who want it. They can embellish it any way they want, but it would come to them with the basic numbering schema and whatever info you want to get them started. Just let me know if you want me to do this.-Blaine”
On ‘Getting Started’, Zenith 601XL builder and flyer Phil Maxson writes:
“After having created a rather complex spreadsheet for the nuts and bolts needed for the build, I’m pretty familiar with what would be needed to create the full itemized list in a spreadsheet. I would love to create that for you. Would you be willing to let me do that?-Phil”
Blaine and Phil- I appreciate the offer from both of you. Phil has some of this already, so I am going to ask him to work on it a bit and come up for numbers on the five samples in the last instalment. Blaine, I know your really good at this stuff, but I want to stay on your 750 project, we need a few more of these to come on-line in 2013.-ww
On ‘Getting started’ builder Bruce Culver writes:
“You know, William, the thing of it is, the Panther billet crank for the Corvair engine is actually a work of art when you look at it. Just look at the photos – things like this end up in the Museum of Modern Art as examples of the best in industrial design. It is absolutely beautiful, as is the notion that you will never have to wonder about its history or previous use or care…..Bravo! It would almost be a shame to seal that inside a case, but I have no doubt it’s what I’ll be using. I was trained as an artist and wouldn’t buy “ugly”. Jeez, that’s pretty…..”
Bruce, I have picked up and carried around in my hands hundreds of Stock corvair cranks in the last 25 years. They weigh 26 pounds, and they are not hard to grasp with one hand, even if they are oily. I have given Dan a hand with some of his new cranks and carried them with protective oil on them. They are so smooth to the touch as to be noticeably harder to carry one-handed. They not only look good, they actually feel good to the touch. Lexan top cover? Maybe.-ww
On ‘Getting Started’, builder “Jaksno” writes:
“This is an awesome series! You are a lot like a world-class coach. Much appreciated. I’ve seen the information on the main website, of course, the EAA webinar, and more. But this ‘review’ of sequential process with highlighted decision points couched in logical recommendations is gold. Thanks!”
Friend, thanks for the positive energy. when dropping us a line please let us know your name and what you are thinking of building.-ww
On the topic of Corvair College #25 in Leesburg FL, Builder Jim Nelson Writes:
“So where is the sign-up place. I’d like to visit the College at Leesburg FL. I could not find where to do this—Jim”
Jim, we are going to have more info shortly. I am the guest speaker at the Leesburg EAA chapter, 9am Saturday the 26th if you are in the area. We will college details here after I return from the meeting.-ww
On the topic of Corvair College #26 in California, Builder Ron Applegate writes:
“Hi William, Ron Applegate here. You speak of a CC in Chino…any idea of a date for the College yet? At least two of us here at Rosamond. Thanks…”
Ron, We are looking more at May than any other month. I have a number of factors in the decision, including Weather (we had considered March) and other shows. I have bi-weekly conferences on the phone with the two people who are in on the planning, and we will let you know as fast as we get past a few variables.-ww
On the topic of Corvair College #2X Builder Douglas Cook writes:
“Any plans for another college in the Pittsburgh PA area? I went to #20 in Hillsdale and would like to attend another not too far away.”
Douglas, One of the things we want to do in 2013 is the “Corvair air tour” I mentioned in the last mail sack. If we can get this in gear for the summer, we will certainly pass through your area. Phil Maxson has mentioned wanted to have a Jr. College at his place in NJ. Lots of good ideas, but I have to balance them with regular work and orders.-ww
On the topic of ‘Intakes and internet myths’ Zenith 650/2700 Builder and PhD manufacturing engineer Becky Shipman writes:
“Simple procedure for criticism of earlier engine designs: 1) Understand the goals and motivations of the person who did the design. 2) Assume he knew what he was doing based on available technology at the time. 3) Then look at what has changed between now and then, and then point out why his assumptions are no longer valid. 4) If one assumes everyone who came before them was stupid, one will never learn anything beyond what one can come up with oneself. 5) By and large, I think the people who built airplanes and engines 50-75 years ago were really smart but working off a much smaller technology base, with more limited materials. 6) Their stuff still needed to work, and if it didn’t it was relegated to the scrap heap. “ToolBuilder” clearly is unable to learn from the intelligence of others, and will therefore never be smarter than he is now. 7) A pity he feels the need to demonstrate this on such a regular basis.- Becky”
Here we have a tiny group, the Case. I may later break down the case into smaller more descriptive elements, but for now, it gets the job done. Now, there are a lot of notes that can be applied here, but keep in mind we are just looking at the overview big picture. The one note that I want to point out is that the case has no machine work on a 2700/2850 but the six bores in the case for the cylinders must be machined larger on a 3,000 cc engine. Of course, this is done before it is assembled.
Case Group (1200)
1200- Case -2 halves with studs-
1201- Main case bolts -8-
1202- Pipe plugs for oil galleries -2-
Now, let’s get a look at the four parts so far and think about putting a case together. Using just these numbers as a check list and something of a road map, any builder can put together a plan to assemble their case at Corvair College #25. Actually all the effort to get to that stage goes into the prep work, cleaning and a little shopping. It you lay out all the properly prepared components from groups 1000, 1100 and 1200 in front of me on the bench, and get me an assembly stand and my trusty Snap-on torque wrench “Excalibur“, I can assemble the case in about 45 minutes.
Now I say this in bad conscience because I once took 2 days to do it. There was a tiny ding in one of the bearing surfaces that was putting a small amount of extra drag on the turning crank and bothering me. I took it apart 6 times to find it and make it right. Keep in mind, it’s not a contest, the winning score is being happy with it, and any amount of time it takes between 45 minutes and 48 hours is fine. BTW, everything we are talking about here is in our engine assembly DVD #1 that covers building up a case.
Going back to the first part of this series we talked about crank selection. Lets look at some samples bringing all of this together and see what large variations of choices are available to builders,
Builder ‘Allan Able’ elects to use a Moldex prepped crank, and put off a 5th bearing for now. Lets say his crank has a reasonably good gear on it that doesn’t need replacement. He is going to use the low expense route laid out in the Camshaft section of Part #4
Builder ‘Bob Baker’ elects to use a Weseman prepped crankshaft with a gen 2 bearing hub installed. He is going to keep his used gear from his crank. He is going to get a Clarks standard cam gear, he is going to put in on a re-ground cam himself.
Builder ‘Chas. Charlie’ elects to use a Weseman prepped crankshaft with a gen 2 bearing hub installed. He is going to elect to have a new gear on his crank. He is going to get a Clarks failsafe gear, installed by clarks on a new cam.
Builder ‘Davie Dog’ elects to use a Weseman New billet crankshaft with a gen 2 bearing hub installed. He is going to elect to have a new gear on his crank. He is going to get a Clarks failsafe gear, installed by clarks on a new cam.
Builder ‘Eddie Easy’ elects to send his case and crank to Roy at Roy’s Garage.com. Roy is going to rework his stock crank, install a Roy bearing and use a failsafe clarks gear on a new cam.
In the next few parts we will take a look at how Allan, Bob, Charles,Davie and Eddie are doing on their projects.-ww.