Builders:
Below is the direct link to the College #25 registration page. While it is not required, having people sign up really helps with fine tuning the event logistics. Please take the time to register if you are planning on attending. If you are thinking about heading in, but are not quite sure you can make it, I suggest registering anyway. It is better for us to overestimate the attendance in planning.
As always, a big thank you goes out to 601XL builder Ken Pavlou for setting up the online registration again. Ken and I are pictured below at CC#14, for which Ken was the chief organizer. Ken has done a lot for us, all the way down to setting up this blog/Web page.

Above, I introduce our local host Ken Pavlou at Corvair College #14. Online he likes to be called “The Central Scrutinizer,” a character who is an omniscient narrator in the Zappa opera “Joe’s Garage.” Outside of the Corvair movement, Ken has a long list of accomplishments: Emigrating from Greece at age 8, he has gone on to earn an electrical engineering degree, become a registered nurse and skilled pilot. Happily married and the father of two, he’s also the State Ballroom Dancing Champion of Connecticut (no kidding), and he could earn a living doing stand up comedy. Not bad for a guy who’s barely in his 40s.
Builders:
Kitplanes magazine covered alternative engines in an article that was released a few days ago. Dan and Rachel Weseman asked that I clarify a misunderstanding from the article. As it appears, some people thought I was implying that I had developed all the things I mentioned. My intention was only to highlight developments in the Corvair movement in general. Although anyone reading my Web site knows the following, I will just say it here plainly:
I had nothing to do with the development of the Weseman billet crankshaft. Dan and Rachel have kept the manufacturer’s ID private, and I do not even know who they are.
I had nothing to do with the design nor development of the Panther either.
I have assembled engines with the billet crank, and can attest they are great pieces. I helped Dan with some small tasks on the Panther, but nothing more than anyone would do for a friend building a plane, nothing he couldn’t have done himself. Really, my sole contribution in either of the above was to say positive things about the work of friends.
Dan also pointed out that I have a long history of illustrating out how LLCs are used by bad people in our industry to evade responsiblity. He thought it would be fair if I pointed out that LLCs also serve the function of protecting good people from frivolous legal action. Dan and Rachel have their work under a LLC, and would like people to hear about the positive side, that many good, successful firms in our industry are organized this way. My goal was not to demonize LLCs, but to get builders to develop their own “buyer beware” attitude. In the end, smart people already knew this, and bargain hunters who didn’t care who they dealt with were not swayed by anything I wrote, so the writing probably had little or no effect anyway.
To avoid future misunderstandings of this sort, builders should just get their information directly from Dan and Rachel. It is their hard work, and it’s obviously best explained by them. I am still a big fan, it’s great stuff, but we can just read about it on their own site, http://flypanther.net/
-ww
Builders,
Below I have stripped down the new numbering system to just the group headings. Now it is forming something of a check list for a builder. Without the details drawing your attention, you can get a bigger picture of the build as a path.
In this segment I want to show builders where the primary sources are for people finishing most engines today. Again, this isn’t a detailed shopping list right now, It is just a big picture overview of the best route to success now days.
If the task of building still looks long even with all the details removed, first note this: Groups 3400 through 4300 are in this color brown. They are best understood as the airframe installation part of the engine build. If your goal is to get an engine running on the stand at a college, you will not need any of the parts from these groups yet. So lets stay focused on the groups through 3300.
Next, understand that you will not need to use all 34 of the other groups to have a running engine, There are 3 different 5th bearing choices listed, Dan’s is 3000 in blue, Roy’s is 3100 in green, and mine is 3200 in black. There are other choices on oil systems, charging systems, and other parts that mean a running engine is built out of roughly 28 groups.
Every group that most builders today get from Dan is coded in blue. Looking at Group 1000, it is blue because Dan is now processing the majority of cranks going into engines, and supplying a flow of new billet ones. He isn’t the only place, Moldex is still doing cranks, but I want this list to focus on what is popular now, not every possible path. Shortly, Rachel is going to have the same numbering system on their website as we use here to make processing easier to follow.
Parts from Roy are coded green and those from Mark at Falcon are coded red here. I left everything else in black. A little later I will introduce our own detailed parts list with new numbers, but for now, the majority of the remaining items in black are from us or through basic sources like Clarks.
While getting this overview, feel free to go back and look at the 20 parts I wrote in the last 60 days under the heading “Getting Started in 2013.” They provide an in-depth look at builder choices for the Groups 1000-1600. This is what the new numbering system is about; having the ability to have a good overview of the process by looking at the checklist below, then getting a more detailed look at each step and the required parts by studying the full list presented in the two previous parts, and finally, having each component numbered so that you can read and understand anything I share about my experience on that exact part, without loosing your place on where that specific part will be serving in your own engine build.
In the next segment, I am going to build up some typical engines and show exactly which groups they draw on, and in which order you work them to get to the finish line of a running engine this season.
.
(1000) Crank group
.
(1100) Cam group
.
(1200) Case group
.
(1300) Piston and rod group
.
(1400) Cylinder group
.
(1500) Head group
.
(1600) Valve train group
.
(1700) Head clamping hardware
.
(1800) Steel engine cooling baffles
.
(1900) Valve Cover Group
.
(2000) Rear oil case group
.
(2100) Oil pump and regulator group
.
(2200) Oil Pan Group
.
(2300) Front cover group
.
(2400) Starter group
.
(2500) Hub group
.
(2600) Top oil group
.
(2700) Oil cooler group
NOTE: If you opt for group 2700, then delete group 2800.
.
(2800) Heavy duty oil cooler group
NOTE: If you opt for group 2800, then delete group 2700.
.
(2900) Standard charging system group
NOTE: If you opt for group 2900, then delete group 2950.
.
(2950) Rear charging system group
NOTE: If you opt for group 2950, then delete group 2900.
.
(3000) Weseman 5th bearing group
NOTE: If you opt for group 3000, then delete the 2300 group. Contact FlyWithSPA.com for more information.
.
(3050) 5th bearing oil line group
.
(3100) RoysGarage.com 5th bearing group
NOTE: Typically, builders selecting this option will be fulfilling the following groups: 1000, 1100, 1200 and deleting 2300. Contact Roysgarage.com for detailed pricing.
.
(3200) William Wynne 5th bearing group
NOTE: This bearing takes the place of groups 1000, 1100, 1200 and deletes 2300. Bearing system is not in production at this time.
.
(3300) Ignition group
.
(3400) Airframe ignition group
.
(3500) Airframe charging group
.
(3600) Intakes and carburetors
.
(3700) EFI Electronic fuel injection
Note: included only for later discussion.
.
(3800) Mechanical fuel injection
Note: included only for later discussion.
.
(3900) Stainless exhaust systems
.
(4000) Propellers and spinners
.
(4100) Baffling and cowls
.
(4200) Motor mounts
.
(4300) Airframe fuel systems
Builders:
Here is the second half of the revised numbering system:
I revised the 2600 group at 8:30 pm est 3/21
I revised the 3300 group at 10:25 pm est 3/21
Starter group (2400)
2401- Starter
2402- Starter brackets w/hardware
2403- Tail bracket
2404- Fine gear
2405- Top cover
2406- Top cover gasket
2407- 5/16″ top cover hardware
2408- Ring gear
Hub group (2500)
2501(A)- Gold hub
2501(B)- Short gold hub
2501(C)- Black hub
2502- Hybrid studs and washers -6-
2503- Safety shaft, nut, washer and cotter pin
Top oil group (2600)
2601 (S)- Standard Gold Oil filter housing with 5/16″ hardware
2601 (R)- Reverse Gold Oil filter housing with 5/16″ hardware
2602- Oil filter housing gasket
.
Oil cooler group (2700)
2701- Stock oil cooler
2702- Oil cooler mount
2703- Oil cooler mount gasket
2704- Oil cooler O-rings
2705- Oil cooler mount bolts 5/16″
2706- 3/8″ oil cooler mount bolt
2707- GM oil cooler side baffling
2708- Outboard oil cooler mount bolt
2709- Oil filter nipple (20mm)
2710- Oil filter
Heavy duty oil cooler group (2800)
2801- Heavy duty aircraft oil cooler
2802- Gold sandwich adapter
2803- NPT to -6 fittings -4-
2804- AN-6 hoses to cooler
2805- Cooler block off plate and hardware
2810- Oil filter (same part as 2710 filter)
NOTE: If you opt for group 2800, then delete group 2700.
Standard charging system group (2900)
2901- Front alternator bracket set
2902- Mounting hardware
2903- Permanent magnet alternator
2904- Altermator mounting hardware
2905- Drive belt
NOTE: If you opt for group 2900, then delete group 2950.
Rear charging system group (2950)
2951- Rear alternator bracket
2952- Mounting hardware
2953- Permanent magnet alternator
2954- Alternator mounting hardware
2955- Drive coupling
NOTE: If you opt for group 2950, then delete group 2900.
Weseman 5th bearing group (3000)
3001- Bearing kit (designed for short gold hub 2501B)
3002- Alteration to standard gold hub (2501A)
3003- Alteration to black hub (2501C)
NOTES: Selecting this bearing option allows deleting the 2300 group. Contact Dan Weseman directly at FlyWithSPA.com for more information.
5th bearing oil line group (3050)
3051(A) – Oil feed line & fittings, Standard oil filter housing
3051(B) – Oil feed line & fittings, Reverse oil filter housing
RoysGarage.com 5th bearing group (3100)
3100- Bearing system assembly, Alteration to gold hub, oil feed line and fittings and modified starter brackets, etc. NOTE: Typically, builders selecting this option will be fulfilling the following groups: 1000, 1100, 1200 and deleting 2300. Contact Roysgarage.com for detailed pricing.
William Wynne 5th bearing group (3200)
3200- Bearing assembly system and sub components
NOTE: This bearing takes the place of groups 1000, 1100, 1200 and deletes 2300. Bearing system is not in production at this time.
Ignition group (3300)
3301 (E/P)- Electronic/points distributor with gasket
3301 (E/P/X)- E/P Deluxe w/ connector, studs, and gasket
3301 (D-P)- Dual points distributor assembly with gasket
3302- Hold down clamp, spring and nut
3303- Secondary wire set
3304- Sparkplug set -6-
Airframe ignition group (3400)
3401- Ignition coils -2-
3402- Condensors -1 or 2-
3403- HT switch unit (MSD)
3404- Coil to switch wires
3405- HT pass through
3406- Coil to pass through wire
3407- Pass through to distributor cap wire
3408- SPDT-DPDT switch
3409- Ignition fuse box
3410- Nason switch
3411- Tach pickup
Airframe charging group (3500)
3501- Voltage regulator
3502- PMOV
3503- Master solenoid
3504- Power bus/fuse box
3505- Main electrical pass through
3506- Battery
Intakes and carburetors (3600)
3601- Intake manifolds
3602(A)- Marvel MA3-SPA
3602(B)- Stromberg NAS-3
3602(C)- Ellison EFS-3A
3602(D)- Sonex AeroCarb – 38mm
3602(E)- Zenith 268
3602(F)- Rotec #3
3602(G)- 1 barrel Carter downdraft
3602(H)- Reserved
3602(I)- Reserved
3603- Carb heat
3604- Air filters
3605- Throttle cables
3606- Primers
EFI Electronic fuel injection (3700)
3701- FlyCorvair/Falcon
3702- RoysGarage
3703- Johnson/Holley
Mechanical fuel injection (3800)
3801- Airflow performance
3802- Precision systems
Stainless exhaust systems (3900)
3901(A)- Zenith 601/650/750/705 system
3901(B)- Universal #1 – KR-2, 2S, etc.
3901(C)- Universal #2 – Piet, Kitfox, Wagabond, etc.
3901(D)- Universal #3 – Tailwind, etc.
3901(E)- Reserved
3901(F)- Reserved
3902- Mufflers
3903- Y-pipes
Notes on turbo/321 pipes
Notes on iron manifold systems
Propellers and spinners (4000)
4001- Vans 13″ spinner assembly
4002- Front spinner bulkhead for Warp Drive props
4003- Warp Drive props
4004- Warp Drive mounting hardware
4005- Wood prop crushplate
4006- Sensenich props
4007- Tennessee props
4008- Reserved
4009- Reserved
4010- Reserved
Baffling and cowls (4100)
4101- Baffle kits
4102- Universal nosebowl with round inlets
4103- Zenith cowling
4104- Eyebrow cooling
4105- Rubber baffling seal
Motor mounts (4200)
4201(A)- Zenith 601/650 mount, all models
4201(B)- Zenith 750/705 mount
4201(C)- Pietenpol mount, high thrust line
4201(D)- KR2/2S mount, conventional gear
4201(E)- KR2/2S mount, tricycle gear
4201(F)- Custom mounts
4202- Tray and spools
4203- Bushings
4204- Bolts, nuts, clips, tubes
Notes on weight and balance
Notes on Cleanex mount, Panther mount
Airframe fuel systems (4300)
4301- Firewall pass through
Notes on gascolators, valves, braided lines
Note, group 1000 was revised at 6:15 pm est 3/21
Note, group 2200 was revised at 8:50 pm est 3/21
Builders:
Here is the first half of the revised numbering system. I will have the second half out later today. After that we will have a builder check list, sample build options based on the ‘Alan Able- Eddie easy’ models we discussed last month, I will introduce boxed ‘kits’ that will cover whole groups, and we will revise our parts catalog to reflect these new numbers. All on target to get done this week. Good thing I broke my new years resolution to drink less coffee. Everyone should print out copies of the posts in this series for their own shop build note-book. If you are heading to CC#25 or to sun n fun, having these in your hand will allow us to cover a lot of ground and take notes for your particular plan of progress. When I am standing at Sun n Fun, and guy has a notebook in his hand, and right beside him is a guy who claims to have followed our webpages but has no idea about this numbering system, I am going to be polite to both of them, but who do you think is going to get the bulk of my time? Which guy gets a regular answer, and which guy gets me to dig out the rear oil case and show him the flow pattern in detail?….. Correct, the guy who brought me another coffee……Just kidding.
Crank group (1000)
1001 (A)- Crank (8409 mark, GM)
1001 (B)- Billet Crank (Fly5th Bearing)
1002- Crank gear
1003- Crank gear key
1004- Crank gear gasket
1005- Rear keys -2-
1006- Fuel pump eccentric
1007- Spacer
1008- Bronze distributor drive gear
1009- Oil slinger
1010- Main bearings
1011- Connecting rod bearings
.
Cam group (1100)
1101- Cam
1102- Thrust washer
1103- Key
1104- Cam gear
1105- Hydraulic lifter set -12 total-
1106- Cam lubricant
1107- ZDDP oil additive
.
Case group (1200)
1201- Case -2 halves with studs-
1202- Main case bolts -8-
1203- Main case nuts -8-
.
Piston and rod group (1300)
1301- Piston set with wrist pins
1302- Ring set
1303- Connecting rods -6-
.
Cylinder group (1400)
1401- Cylinders -6-
1402- Base gaskets -6-
1403- Head gasket set
Head group (1500)
1501- Pair of heads with seats and guides
1502- Valve spring set
1503- Retainer set for intakes and keepers
1504- Exhaust valve rotators and keepers
1505- Intake valves -6-
1506- Valve seals
1507- Exhaust valves -6-
1508- Exhaust stacks -6-
1509- Welded on intake pipes
.
Valve train group (1600)
1601- Pushrods -12-
1602- Pushrod tubes -12-
1603- Pushrod O-rings -24-
1604- Rocker arm set -12-
1605- Rocker balls -12-
1606- Nuts -12-
1607- Lock nuts -12-
.
Head clamping hardware (1700)
1701- Guide plates -6-
1702- Stud O-rings -12-
1703- Rocker studs -12-
1704- Upper head nuts -12-
1705- Upper head washers -12-
.
Steel engine cooling baffles (1800)
1801- Under cylinder cooling baffles -2-
1802- Clips to retain engine cooling baffles -4-
1803- Baffle between #1 cylinder and distributor
1804- Baffle between #2 cylinder and oil cooler
.
Valve Cover Group (1900)
1901- Valve covers -1 pair-
1902- Hold down clamps -8-
1903- Hold down hardware 1/4″-20 -8-
1904- Valve cover gaskets -2-
1905- Oil fill cap
.
Rear oil case group (2000)
2001- Rear oil case casting
2002- Rear oil seal
2003- 5/16 hold down hardware
2004- 3/8 hold down hardware
2005- Case to block gasket
2006- Harmonic balancer
2007- Balancer bolt and washer
.
Oil pump and regulator group (2100)
2101- Oil pump assembly
2102- Oil pump gaskets
2103- Oil pressure regulator piston
2104- Oil pressure regulator spring
2105- Oil pressure regulator plug
2106- Plug washer
.
Oil Pan Group (2200)
2201 (B)- Gold billet Oil pan
2201 (W) – Fly weight welded Oil pan
2202- Oil pickup
2203- 1/4″-20 hardware -19-
2204- Drainplug
2205- Oil pan gasket
2206- Dipstick
2207- Dipstick bracket
.
Front cover group (2300)
2301- Front cover
2302- Cover to case gasket
2303- Front oil seal
2304- 3/8″ hardware -9-
Builders, here is a sample from the mail box:
On the topic of a Pietenpol/Corvair notebook, Harold Bickford writes:
“William, The Pietenpol/Corvair notebook is certainly on my want list. Tech data in a handy, concise format would be a great reference tool for building and flying. Motivational aspects could include the fun of the hunt for parts, making of assemblies and just the pure satisfaction of seeing a project come together. Actually visiting with builders and fliers at events becomes part of that process. It is far more than numbers, nuts and bolts. It is a goal with a journey into learning. The reward is being able to share that experience with others.and even motivate them to pursue the path.
In my case that goes back to high school days in 1966 when the pages of Air Progress covered an event in Rockford, IL for an outfit known as EAA. An old style airplane called a Pietenpol Air Camper was one of those homebuilts pictured. It doesn’t really matter why it took so long; the point is that the vision endured. On to Brodhead and beyon…Harold”
On the topic of Real Goals, builder Lyle Fast writes:
“William, I wonder if you asked the same old aviator if he ever knew a dedicated, competent, knowledgable, experienced and with good judgement pilot that died in his aircraft? I believe he would have known some maybe many. I believe it is not humanly possible to control completely the outcome of activities influenced by the forces of nature. Some of us will die in our aircraft, denying this or looking for things to blame is a normal response. Deciding that the activity(flying) is good enough to die for is worth examining. If each act of aviation(engine building, preflight etc) is viewed as possibly your last dance on earth surely we should all be motivated to make it the best dance we can! -Lyle”
“Lyle, I agree with you 100%. There will always be risk, but it is our task to eliminate unnecessary risk. Because I have been in aviation for 25 years, and went at it ‘full throttle’, and my wife is also an aviator (and a lot more charming than me,) we have had more friends in this than any human deserves. With this abundance of adventure seeking friends and the passage of time, we have lost many of them. I only count people we knew well enough to have stayed with them or reverse. I stopped counting when we got to 12. These people were smart, skilled, and understood what they were doing. About 3/4 of the accidents were preventable. People with good judgement who couldn’t find it that day, something left undone, weather. 1/4 was unavoidable, ‘wrong place, wrong time’. This said, None of these people were harmed by knowing too much, being too skilled, or having excessive mastery of their craft and situation. Without a doubt, we could not possibly count the amount of times our friends have avoided harm or have been spared it by their understanding, knowledge, skills and judgement.-ww”
On the same topic, Builder Bruce Culver writes:
“William, here is a thought I left on Mac’s blog ‘Left Seat’ in SA. It is based on my 25 years in military defense logistics, and the general direction of the GA pilot/airplane population:
One thing that seems to have escaped a number of people in the business: as the number of active pilots and planes declines, there is increasing pressure on the support infrastructure for GA aircraft. When the number of customers and planes falls to a sufficiently low-level, you’ll see A&P mechanics going out of business, FBOs closing, engine and prop shops consolidating and/or closing, radio and instrument shops ditto. It will take time, but gradually the support structure for GA will slowly disappear, and at some point, even the doctors and bankers in their $750K fancy airplanes won’t be able to have them serviced – and what happens if you have an AD that requires immediate compliance, and no way to have the work done? Ask not for whom the bells tolls – it tolls for thee….. The real irony here is that the people who will be least affected by this possible turn of events are those who have built their airplanes themselves, possibly even built their engines themselves, and who have the aircraft repairman certificates to prove it.”
On the topic of the new numbering system, 750 builder Blaine Schwartz
“Thanks William, you speak the bold truth! Now that I have built my engine (at CC#22). I look forward to attending more Corvair Colleges so I can better my skills at timing distributors, learning how to use a differential compression tester, and understanding how to conduct a 100 hour inspection and helping other builders. Building is great, but when I have completed building and am flying, I surely want to be able to keep my plane in the air and completely safe! Blaine “
Also on the topic of the new numbering system,, Zenith builder Marcus Wegmeyer Writes:
“William, I want to applaud you on the new numbering system and goal to develop a checklist to build the engine. I’m a new builder, my Zodiac CH 650 is a child in the womb being nourished, growing, and put together bit by bit. The Corvair is the engine of choice. Your check list will certainly help move that part of the project along in an orderly fashion. I’ll only have 1 day at Sun n Fun but it is my plan to stop to meet you and introduce myself as well. Marcus, Gaylord, MI”
Parting shot, follow-up on an earlier letter, Piet Builder Dave Aldrich shares:
“I wasn’t being serious either, ref the ice cream/Dockers/Polo shirts comments. I did buy one pair of Dockers new (Kohl’s, on sale, 30% off) for my (last) wedding which took place on a dock at a friends house down in Tavernier (mm 92, south of Largo). The color matched my shirt and sandals. Side story: The “best man” and I won the National Boatbuilding Challenge last summer in Belfast, Maine using the motto “Old age and treachery will overcome youth and skill.” Built a usable skiff to plans in 2 hours 45 minutes. Definitely NOT aviation or cabinet quality joinery but it floated well enough to race across the harbor. We both have seaplane ratings so it does have an aviation tie-in.- Dave”
Builders:
Below is a sample of the 1100 group of the new numbering system. We saw this earlier, in the ‘Getting Started in 2013’ series I wrote last month. I am going to slightly change the system of numbering to make engine building easier to organize. It is a subtile change, but an important one. I pick this simple group to show the before and after, and to explain why. Very shortly I am going to come back with the final revised numbering system, and print it all out here. We are going to change our own parts numbering system on our catalog page on our main website to match the new system, and we will have a vastly better organized system for builders to work with that will provide a very orderly path to a running engine.
Below is the original numbering system from last month. Note how the group is 1100 and also the camshaft itself is part number 1100.
.
Cam group (1100)
1100- Cam
1101- Thrust washer
1102- Key
1103- Cam gear
1104- Hydraulic lifter set -12 total-
1105- Cam lubricant
1106- ZDDP oil additive
.
Ok, here is the change: Notice the group stays the same, 1100, but everything moves down one number. below this I will explain the why of it.
.
Cam group (1100)
1101- Cam
1102- Thrust washer
1103- Key
1104- Cam gear
1105- Hydraulic lifter set -12 total-
1106- Cam lubricant
1107- ZDDP oil additive
.
Now, picture yourself building an engine with the new numbering system. As I will show everyone shortly, there are 40 different groups, each with their sub component numbers. We are going to have a checklist for builders with the 40 groups on it, so a guy heading to a college to close his case will know that he needs to have all the sub components so he can ‘check off’ groups 1000, 1100 and 1200 from his list.
The new change eliminates confusion between a builders speaking of ‘having part 1100’ which was just the cam, and ‘having group 1100’ which are all the items listed above. The simple number change above fixes this.
Second, we are moving toward a system where we will be able to offer an entire group in one box, instead of just some parts of the group. for example, Lets look at the Oil Pan Group (2200).
.
Oil Pan Group (2200)
2201- Oil pan
2202- Oil pickup
2203- 1/4″-20 hardware -19-
2204- Drainplug
2205- Oil pan gasket
2206- Dipstick
2207- Dipstick bracket
.
Traditionally, a builder bought a pan and an install kit from us, and ended up with all the things listed except for 2205, 2206, 2207. respectively, his gasket was from a gasket set like the clarks 120ww set, but we are moving toward getting builders to look at the gasket as a part of the group, because big sets often have things like front seals that 5th bearing builders don’t use. In this case I want builders to just have a clarks c-199 gasket. We have long told builders to get the Ford 302 dipstick and cut it down. This hasnt been a problem, but I could just get a giant stack of them and cut them all down to the correct length in 30 minutes. The tab is a small bracket the stabilize the top of the dipstick to one of the 5/16″ top cover bolts. Easily hand-made if the builder wishes, but I want to have laser cut ones available because they are cheap enough and I want builders to focus on the big things, not a detail like fabricating this small part, especially at settings like Colleges.
Thus, we are shortly going to revise our catalog page to have something called a “Complete 2200 group”, which will have all of the parts of this group in one box. We will have clearly explained letter code suffixes, so a builder can directly order a 2200B, which will be the whole group with a Gold Billet pan, and we will also have a 2200W, which is the whole group with one of our welded pans. Of course, we will still have the Gold Billet pan by itself, and it will have part number 2201B.
You don’t have to memorize any of this, we will spell it all out in detail, but I just wanted to give builders a look ahead and a specific sample so that we can understand the system and where we are headed with it. I personally think that it will make a big difference on the accessibility of engine building.
Now, follow this next part closely, because it is the whole reason why I have spent a year developing this new system. I want more builders to get more focused on developing their fundamental understanding of the Corvair engine, and become much better operators and mechanics on them. Right now, we are doing good, the average Corvair builder is a Motorhead/genius when his engine is done, if we compare him to the average guy that just bought a buy-it-in-a-box imported engine. But I am setting my educational standards higher than that. I want every guy to get the most out of building his engine in terms of a learning opportunity.
Here is how the new system serves this: right now, too many builders view the engine building task as collecting the parts, assembling them, and getting it done. Thats fine, but I am not after improving builders shopping/scrounging skills, nor am I interested in having builders focus much thought on making a dip stick tube bracket. I want builders to really know things like how to install and time distributors, how to set valves once, how to use a differential compression tester, how to do a valid 100 hour inspection, when to preheat in cold weather and why. These things are the type of things that really good A&P mechanics all know about the types of engines they master, and there is no reason why any person in homebuilding for the right reason should accept knowing less. Having the parts system better organized and group parts more accessible gets more people away from the parts perspective, and get them to a mindset where they are focused on improving their real skills at being the true master of the engine they fly.
That may not be the goal of 90% of the people wandering around in experimental aviation, but let me tell you this with 25 years of hindsight of doing this stuff every day: The people who get something out of experimental aviation, really know it’s rewards, are the people who came here to learn. To really learn, not just know the answers on the quiz, or to sound smart in hangar BS sessions, but to be able to walk out to their airplane to preflight it and know that they are not taking a random chance, nor hoping some one else knew what they were doing. To walk out to your own plane with confidence because you are the master of it, and you are the only person you will be counting on today, and you are calm because you know that you invested the time and effort to really learn something, and you have made your plane right with this knowledge. That is getting something out of experimental aviation that is worth all the time in your shop, all the money you spent, all the things you sacrificed to do it.
And the other 90%? I hope God looks after them, or at least their families. Sound harsh? Try this: go to your airport today, find the oldest aviator there, a guy so old he flew radials commercially, the guy who is likely to have seen just about everything in flying, and ask him just one thing. Ask him if he ever saw a single person hurt in aviation because they knew too much about the machine they were operating, that their mastery was too high for their own good, that a person with less skills would not have been hurt. I don’t care who you speak to, no one has ever seen this. Today, somewhere in print, some moron will say that buying a new Lycoming or Rotax is the path to safety. What a joke; there have certainly been ignorant users, thinking they could buy their way to ‘safety’, who were shortly thereafter harmed by their allegedly ‘safe’ item. Anyone with a brain and a speck of honesty will tell you that the only path to safety is Understanding, Skill ,Knowledge and the Judgment to apply them. Anyone who says that you can buy some product and not have to be so concerned about U-S-K-J is a dangerous fool.
Ernest Gann may have been aviations greatest writer. In “Fate is The Hunter,” preface states that flying is a kind of war story, where “the designated adversary always remains inhuman, frequently marches in mystery, and rarely takes prisoners.” He wasn’t kidding or stretching the analogy. The book has several pages of abbreviations in small print, which you only understand later are a list of all the people he knew who were killed flying. Gann and his contemporaries where doing far more dangerous flying than we are, but it is fair to say that they were also professionals who were vastly more talented that average pilots today. I can tell people the risk typical GA pilots face today is a small fraction of what Air Transport pilots faced then. What is your response? 90% of EAA pilots take this to mean that they can get by aspiring to a lot less than those early aviators knew. If you are part of the 10% that understands that your risk will only be far lower than theirs if you work to develop the same Understanding, Skill ,Knowledge those men had, then welcome, I have things I can share with you. You will not need God to look after you, you can do it with the brain you received.
I think Gann’s analogy holds. You are headed to a combat of sorts. My goal is to really teach you how your weapon works. To take it all apart, be able to clean and maintain it, spot trouble before it happens, put it back together, and how to fine tune it and operate it with great skill that only comes with intimate knowledge of a machine. Even though the task ahead is serious, you will be prepared, and harm will not come to you because you didn’t know your weapon in the conflict. Contrast this with the prevalent mentality of 90% of the people in the EAA. Just like everyone else, they are headed to a conflict, but they don’t like thinking about it, “it will be all right” is their common motto. They think they can buy a new weapon, and this will make it reliable, even if they don’t know how to clean it, far less understand it. They think high-tech is some sort of magic armor, a replacement for understanding. They are not the master of their arm, they are just the person holding it. Deep inside they know this, and they suppress that thought every time they meet a well prepared master by blurting out “mine is new, I don’t have to know what you do.” Who do you think is more at risk? In the hours before conflict who do you think will be frightened and who will be confident?
They will never feel what you do when they walk out to preflight their plane. You will be confidently checking your workmanship. A preflight to them a some sort of ritualistic pagan dance they were taught the moves of, by an equally ignorant ‘instructor’, a dance that they desperately hope will appease the gods of luck and chance and keep evil at bay by a method that is unknowable. The real gods of flight, Physics, Chemistry and Gravity, look down from above, unmoved by the little dance. They only respect people who follow their rule book. To Aviators, the book is on the shelf and written in plain language. Dancers who never took the time to learn to read view bad events that happen to the dancers in their troupe as running afoul of luck and chance, fake gods they themselves made. Each of these events looks very different to any aviator who knows who the real gods of flight are, and understand that these gods are just, but never understanding nor merciful.
Are you a person who spends money and hopes for the best, or are you a person who actually likes knowing that your fate is in your own hands, and no one elses’s? This answer matters more than any other in your experimental aircraft experience. Any commentary on risk management, be it in print, in person, or broadcast isn’t worth paying any attention to unless the focal point of it is developing the Understanding, Skill ,Knowledge of the Aviator. -ww
Builders: Here is a sample of the mail:
On the topic of a Pietenpol notebook builder Dave Aldrich writes:
“If you have the Pietenpol “notebook” ready for Brodhead, please set one aside with my name on it. Thanks.”
Dave, I would very much like to get it done of this years event. I have already collected up a lot of material on all things Piet/Corvair, but I am very interested in hearing from Piet builders on what they would like to have included. I would like the end product to be filled with data, but motivational also. I have stories and profiles on many of the current operators like Randy Bush and Kurt Shipman, because I think the diversity of people reflects the individuality of the planes.-ww
On the topic of reading carefully, builder “Jacksno” Writes:
“Excellent admonition re reading comp re all things aviation. I know you’re dead serious in our behalves (there’s a picture), but, “I am going to put an ignition from a go-cart and a Hartzel constant speed prop on my 601XL so it will do 200 mph in cruise at flight level 25, that is just as soon as I pull my first rivet and get a student pilot certificate, ” was just 2 funny! I’m very tempted to add enough bumpers on my car that I could post it there. Seriously, you are a standard-bearer of great value to all of us. Kudos.”
On the Panther roll out, builder Harold Bickford writes:
“Hi William, I remember JFK giving that speech. It was and is inspiring. Dan did his work just as Orville and Wilbur did theirs with the benefit of a larger knowledge base to work from. It is a matter of what Tom Wolfe called “The Right Stuff”. Why would people not want to continue that? Harold”
On the Panther roll out, Zenith 601 builder Brad Boon writes:
“Outstanding post!”
Builder Albert Wilson writes:
“Hello WW, My name is Albert Wilson and I am very interested in the Corvair engine, have been thinking about building a ch701, then a ch750 and now I’m liking the 650 as I keep hearing the 750 has a very poor glide ratio. I got my A&P several years ago from National Aviation and would like to put my training to use. I have done lots of research over the years and the zenith 650 with a Corvair engine looks like the way to go, see you soon, Albert.”
Albert, welcome aboard. While the 750 does have a short glide ratio, it has other qualities that it excels at. The glide ratio and the flare technique are very good reasons for 750 and 701 builders to get type specific training in these aircraft, Zenith has links to people who offer this. The 601/650 are far more ‘stol’ than most general aviation aircraft. With a little bit of practice, they can get in and out of small spaces, and they enjoy a faster cruise speed on the same power. They are both good choices.-ww
On the topic of Floats on snow, builder Roger Pepin writes:
“It’s great that Jeff was busy building and now flying his plane – not getting into internet discussions and taking “advice” from guys like “I seriously looked at the Corvair engines – but decided that with the wide front end of a Rebel – that the faster turning and therefore smaller diameter prop’ ( which you HAVE to use – in order to let the engine get up IN to it’s power band RPM range ) would be “inefficient” on the nose of such a meaty plane ( big front end ) Follow the people who are flying, learn from their experience, soon you’ll be flying.”
On th topic of CC#25, Piet Builder Dave Aldrich writes:
“45 years ago, a good friend maintained that the thing wrong with the US could be traced back to 3 things: white bread, French’s mustard, and American process cheese. His point was that mediocrity should not be a standard. Sort of ties in with your vanilla ice cream, polo shirts, and Dockers reference though I do take partial exception to your vanilla ice cream and Dockers remarks. Good vanilla, while hard to find, does stand on its own as worthy. I have several pairs of Dockers in my closet, all bought at thrift stores for $6 or less, and they work just fine too, grease, paint, and holes notwithstanding. Not one polo shirt on my side of the closet. Can’t say the same about my wife’s.”
Dave, never take comments I make about the social side of things too seriously. I personally love vanilla ice cream. I was just trying to point out that everyone is welcome at the colleges, and we have far more diversity than you see in the pages of flying magazine.-ww
On the “no politics at colleges rule” Zenith 750 builder Charlie Redditt Jokingly writes:
“what about the positive benefits of discussing politics?
1) Provides vigorous cardiovascular exercise.
2) Provides motivation to finish work quickly (so you can get the next word in).
3) Provides relief from work stress (impossible deadlines, flaky hardware, and other factors outside one’s control don’t bother one quite so much after a good political row).
4) Epithets are an excellent way to gain the immediate attention of a colleague.
5) Provides a wider perspective and helps people let bygones be bygones (i.e. your associates are still upset with you, but not so much about the equipment you damaged or bogus advice you gave them).
6) Relieves tedium and provides entertainment for those around you.
7) Provides a deeper understanding of personalities, and allows you to justify your dislike of others for reasons beyond manner of dress or grooming habits, and vice-versa.
8) A carefully crafted remark can be used to a) heighten everyone’s awareness while simultaneously b) stopping all useful work in the vicinity in such a manner that no one notices that you’re just looking for an excuse to slack off.
9) Enhances self-esteem by allowing people a chance to feel smug about themselves regardless of their level of competence.
10) Others might actually have passionate feelings regarding your person. Maybe not positive feelings, but at least they will remember your name.”
Charlie, Have fun now and get it all out of your system before CC#25, because we don’t even make fun of people who are talking about politics at the college. We keep the whole thing off-limits for everyone’s good-ww
On the topic of local ‘experts’, Pietenpol builder Earl Brown writes:
“I have one of those “self styled Corvair experts” in my EAA chapter
When mentioning that I was putting a corvair on my Pietenpol I was told that it was That he made a living working on corvairs and that they were terrible for airplanes, cranks weren’t strong enough and he wouldn’t recommend doing that. I just told him he was welcome to his opinion and walked away wondering if there are really enough corvairs driving around my area to make a living working on them.”
Earl, evidently there are enough ‘experts’ on Corvairs that every EAA chapter in america apparently has one. Take heart, I actually have a guy in my EAA chapter who always tries to tell me about Corvairs like I have never seen one before. He knows what I do for a living, but he can’t stop himself. Last month he gave ne a 4 minute monologue on how the Corvair was designed by Ferdinand Porsche. You are right to just walk away, S.E. Hinton wrote “Even the most primitive societies have an innate respect for the insane”.-ww
West Coast builder Doug Eaton writes:
William,
I sent you a letter about a month ago regarding the cost and parts necessary to assemble a corvair flight engine. Since then, I have noticed that you indicated that you are working on a platform of part numbers and engine profiles to help the builder better prepare for the rebuild of a corvair flight engine. I purchased your manual and learned quite a bit. I am having difficulty locating a late-model corvair engine. I have contacted over a dozen salvage yards in Northern California specializing in older model cars. The typical response to my inquiry is “hell no” we don’t have any corvair engines! William, since you have been at this so long and even though you live on the opposite coast line, I was hoping you or one of your confederates may have a lead for me regarding a reliable source for the engine somewhere in this neck fo the woods. Doug Eaton Redding CA”
Alright all you nothern CA guys, one of you drop Doug an email at: yrlender@aol.com And give him a good source near Redding Doug, keep in mind that running an ad on Craigslist is the most productive way to find an engine, this is how 50% of the people got an engine last year.-ww
Builders;
We received a number of positive comments about the new information board for Zenith/Corvair builders. Notably, one of these was from Sebastien Heintz, president of Zenith. People who have been involved in homebuilding for a long time all understand that reliable and specific information and guidelines, developed directly from testing and field data are the foundation of real risk management in operations.
One of the things that a number of builders missed in the story is the very specific qualification for an invitation to join the group. Only people who have a completed Corvair powered Zenith, and Zenith builders who have a Running Corvair engine are qualified. We received a number of requests from builders that met these specific qualifications, but we also had a number from builders who either didn’t read the original story closely, or wanted some type of exception to be made for them. I would like to politely point out that we have a number of good reasons for the qualifications, and we are going to stick with them.
For the people who didn’t read the story closely, let me say that I write this stuff very carefully, and many of the things I write contain critical technical information on procedures. If you don’t have the time to read things, or your just glancing at it on a smart phone while driving, consider changing the way you approach information gathering on aviation subjects. I will read the newspaper when I am half asleep, but then it comes to reading things from aviation, AD’s instructions, POH’s, FAR’s NOTAMs, etc, it’s all brain cells on deck, no distractions, and taking notes if necessary. In day-to-day life there is no penalty for poor reading comprehension. In aviation, 90% reading comprehension is still a failing score. It is two different worlds, and you have to discipline yourself to treat them differently. Less than 100% reading comprehension has some expensive consequences here. If you missed the part on qualifications, think of it as something of a very valuable wake up call.
For people who asked for an exception, please understand that we are not making any. First, when I asked the original Flyers to join, I said that the board I was asking them to join would only have people on it that met these qualifications. To make an exception is to unilaterally change my agreement with the people who have already joined and shared a lot of their operational data. A number of these people have never written into any other internet discussion group precisely because they didn’t want to have ‘John Q. Cyberspace’ and every other guy with a keyboard telling them they were ‘doing it wrong.’ They agreed to share their information with people who are very likely to use it, and have worked enough to appreciate the accomplishment of a builder with a flying plane. I have many faults as a person, but one thing I don’t do is unilaterally decide to change agreements with people.
Second, this is a ‘board’ in the same sense that the NTSB is a board, meaning that it is a specific group of qualified individuals that are tasked with collecting data on a specific subject. When the NTSB looks into something, they gather data, analyze it, and then put out a finding. Aviators understand and trust the process, and understand why they don’t have every person with a pilot’s licence invited to comment during the process. Likewise, having builders with just a rudder kit and a Corvair core engine in the group would not serve the mission. As well-meaning and interested as these people are, they don’t have their own data to contribute, and they don’t need the operations data before they have a running engine. If you want to be part of the group, chart a plan on how to finish your engine in the next few months. I will be glad to add you to the group. When your work pays off and you are in, you will be glad to be operating in a unit that will never have a guy chime in and say “I am going to put an ignition from a go-cart and a Hartzel constant speed prop on my 601XL so it will do 200 mph in cruise at flight level 25, that is just as soon as I pull my first rivet and get a student pilot certificate.” Your work on your own real engine will set you apart from such people.
If you are a builder of another airframe for your Corvair engine, there are other paths we are working on. Pietenpols are our #2 most popular installation. because of the highly individual nature of each Piet, and the fact that the Piet community already has a fairly good on-line communication network, my goal this year for Piet/Corvair builders is to compile a ‘notebook’ of all the data that we have on the building and operation of the combination, including weight and Ballance data, mount information, cowling designs, prop info, etc. We have most of this already, it just needs editing. The raw material we have looks like it will distill to a 200-250 page notebook. Getting this together is my main writing goal for the period between Sun n Fun and Brodhead this year.
There is a good number of Corvair powered KR’s, but there is not a call for a board like we now have for Zeniths. First, they are already served by the KR net and other sites. Second, KR’s are unique among Corvair powered planes that less than 50% of the flying ones utilize what we call a pure “ww Conversion.” Almost all of the flying KR’s have some piece on them which we made, an ignition, a mount, an exhaust or a hub, and I like to think that these builders all benefited from things that we worked on, but there are very few KR’s that have a complete engine installation that looks like the ones we teach people to build.
The only prominent examples of our style of engines and installations on KR’s are Dan Heath’s and Steve Makish’s. Most of the others still have rear starters, do not have Gold Oil systems. The goal of our Zenith board is to develop and log a lot of standardized data for follow on builders to use. The individual nature of the majority of KR installations doesn’t easily fit the same goal, and I am not in a position to test nor comment on systems we don’t work with nor sell. KR guys are pretty technical savvy and already share a lot of info, and there isn’t a big contribution that I can make to that particular combination on the information front. I am glad to sell the parts that those builders are willing to use, but an information board for them would not be productive.
The modern KR/Corvair era started when we went to the 1999 KR gathering, and a lot of productive interest began at that point. We did not start our work with Zeniths until almost 5 years later. There are actually more KR builders in the EAA than Zenith builders. Yet in spite of a 5 year jump-start, we have six times as many Corvair powered Zeniths in the fleet than Corvair powered KR’s. To my perspective this is mostly due to the fact that almost every KR guy wants to build a ‘unique’ installation. Nothing wrong with that, but it doesn’t get nearly as many planes done as builder selecting a more proven path. People may argue that there are other factors at play on the completion rate, but look at the fact we have had about 30 Pietenpols completed in recent years, and Piet builders have a lot of things in common with KR builders (plans built, orphan design, same time to build, same average budget, individualized planes) but ahead of the firewall, almost all Piet builders have engines that are closely following our guide lines.
For builders of other designs, keep in mind that I am still your primary resource when it comes to putting your Corvair on your plane. We can answer most any question you have, and I am glad to do so. I am obviously going to continue to print a lot of information right here, and there are many other ways we share info with builders, like airshows and Colleges. In most parts of the country, the flying season is just beginning. All it take to make this year productive, fun and rewarding is your own personal decision, right now, that this is your year, and you will make it count. Decide this right now, and you will find me glad to play any supporting role.-ww
Builders:
About two weeks ago, Zenith 601XL builder and pilot Phil Maxson and I formed a private discussion board for the specific topic of installation and operation of The Zenith/Corvair combination. We had been planning this for several months. We used 36 builders and pilots to test the format and get the data base up and running. We are now inviting more members who meet the entry qualifications.
The purpose of the group is to let the 70+ builders who have a flying Corvair powered Zenith that was built within the scope of being a “William Wynne Conversion” to directly speak with each other, compare notes and operational data. While many of these people are friends, I wanted to facilitate them all being able to share information even if they have not had a chance to meet in person. We have further opened up the group to Zenith builders who have a running engine. The logic here is that builders with a running engine are at the point where they can most benefit from being able to question builder who are currently flying the exact combination they are working on.

Above, Phil Maxson and I stand in front of his 601XL at his hangar in NJ. Phil is the ideal person to moderate the new group for a number of reasons; his plane has been flying since 2006, he is very technically savvy and he is a very friendly guy who will maintain a positive tone in all the discussions.
The output of the group is not going to be secret, but it is going to be private. The archives are only directly accessible to the members. The group is not intended to replace any other internet discussion group or forum. Zenith builders and flyer is a great group for Zenith builder in general, but it doesn’t have a setting for pure Corvair discussions. Corvaircraft works for some people, but often information is provided by internet personalities with no actual experience, or people who are not following any of my guidance or recommendations. A number of the pilots of flying Corvair powered planes have told me that they do not want to share their hard-earned first hand experience in a setting where the most common response is from a person yet to buy a core engine telling them they are doing something ‘wrong.’ Our new group allows these successful builders to directly share their experience with others who are far enough through their own project to really appreciate and utilize information from real experience.
The board it set up with many different topics such as weight and balance info, cold weather ops, prop pitch vs performance data instrumentation options, insurance, charging systems and currently about 40 other topics. Members are working to expand the data base on each of these. Every single person, both builders and flyers are expected to have a profile page. There are no mystery names nor random names popping in from cyberspace. Everyone is a serious person with a real goal in aviation. The site can take data in many forms, pictures, graphs, drawings and spread sheets. It is also set up to have video conferences possible. The dialog is friendly, but the site is more of a high-tech reasearch library than a social discussion group or a opinon forum. It has no ‘rules’ per se; Serious people with a common goal don’t need a list of rules, they just need a forum to share real data and ask valid questions.
If you are working on the Zenith/Corvair combination, but have not progressed to the point of a running engine, the new group will still benefit you indirectly. If you have a particular question and would like an answer from the group, you can send it to me and I will enter it into the discussion or share with you some of the data from the files of the group. By rapidly allowing the builders with running engines to bring their planes to the finish line, it expands the fleet allowing more aircraft to be available for first hand inspection at smaller air shows and events. The group is also a very good risk management tool that will work to keep the outstanding insurance rating that our Corvair Conversion on Zenith airframes enjoys. When your engine is up and running we will be glad to send you an invatation to participate in this new forum.
If you are the flyer of a Zenith with our Corvair conversion, and you have not yet received your invitation, please contact Phil or myself by email. We are particularly interested in contacting the half-dozen second owners of these aircraft. If you are a Zenith builder (plans or kit, 701,601,650-750), and you have a running engine, please contact us for more information about joining the group. Signing up is simple and it is absolutely free. There are no costs nor ‘donations.’
Phil’s email is: n601mx@gmail.com