Builders:
Here is background information on my very popular “Supervised Engine Build” program, which I run at my hangar in Florida, eight times a year.
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DESCRIPTION: Eight times a year, I have several Corvair engine builders at my hangar for a 3-4 day training session, where I supervise builders assembling their own engines. When completed, each engine is run on my test stand. I provide the setting, the specialty tools, the expertise and the supervision. Builders do the actual work, hands on. I directly assist to teach work techniques, double check assemblies and to solve problems, but builders are expected to be motivated to learn, and show up having pre-read manuals. The pace is adjusted to each builders needs, and no one need prior experience engine building. The willingness to learn is the only element the builder must have. In the last four years, more than 60 people have gone through the build program here. Every single engine was completed and run. I have recently expanded and reconfigured my hangar to optimize it for Supervised Builds. From 2024 forward, I will be able to train twice the number of builders as previously served.
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WHAT ABOUT CORVAIR COLLEGES? Between 2000 and 2020, I held 50 Corvair Colleges all over the US, even in Canada. More than 1,200 individuals attended these events, they were fun and productive, but required enormous expenditures of travel time and funds, and placed large burdens on local hosts. These Colleges were free, builders only paid a modest fee to cover the catering. In the last years of colleges the increasing presence of people looking for free labor, with no learning motive, No fresh qualified hosts meant two teams of local hosts ended up presenting 40% of all the Colleges, and my traveling thousands of miles with the equipment convinced me that the Colleges, originally planned to last just 5 years, had outlived their effectiveness. I have said this numerous places since 2020, The era of Corvair Colleges are over, I will not host another. We are now in the era of Supervised builds, which I will run from here forward.
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SETTING AND WORK: Supervised builds are done in my hangar in Green Cove Springs Florida, Just south of Jacksonville. The build groups are 3 or 4 engines going together , the start is slightly staggered so the engines reach the test stand at 6 hour intervals. I run the builds in the spring and fall, to avoid the harshest weather. My workshops are climate controlled, but my hangar is not. We work from 9 am until 6 pm every day, with an hour off at lunch. Even for prepared builders, this is the saturation level of learning. At many colleges I worked far later hours, but experienced showed that engines were finished, but learning after 8 hours is minimal. I generally check builders in on Thursday night, and start Friday morning. In most cases, everyone finishes on Sunday. If necessary, I will work Monday and even into Tuesday to complete and test run engines. I do not rush builders, the goal is to learn, and all I ask it they focus on the work at hand. The cost of the build is flat, if the builder takes extra time, the cost remains the same. There is no incentive to rush.
Builders can bring their own hand tools, but it isn’t required. I have all specialty tools here . The test run stand has its own Intake, Carb, prop, cooling baffel, plug wires, coils and exhaust system. Builders do not need these ite,s.
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SIGN UP: Each Event will appear on my “shop” products page as a regular product, with an available quantity of 4. Builders can look at the dates and sign up by selecting one of the slots and paying for it. If you have questions, lets talk about it in advance, so when the Supervised Build date is opened, you already know what you are signing up for
The Next Supervised build is A week away, May 3rd, But it is already full, and has been for several months. I was considering a June session, but I have a lot to do before Oshkosh. July will always be out because of Oshkosh, as September will be out because of The Zenith Home coming. August involves a lot of post Oshkosh follow up, and is very hot in Florida. However, I am going to have at least one Supervised build session in each of October, November, and early December. If necessary, I will add a second December date. The dates of these events and their sign ups will be announced and available on June first.
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LODGING: At Colleges, we had many people camp on site, and it was fun, but didn’t serve learning, as people didn’t get enough rest to keep focused on day 2 and 3. Now, at Supervised Builds, I direct people attending to the Holiday Inn Express Either in Fleming Island (12 mi.) or in Palatka (18 mi.) Well rested builders learn more, are more productive and are safer in the shop setting. Starting at 9 allows getting up, and fed, and previewing the days plan, before picking up a wrench. Stopping at 6 allows the builders to get dinner, reflect on the day, and get rest.
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COSTS: The cost for the Supervised Build reflects how much work goes into a particular build combination. Here are the costs for Supervised assembly and Test run, in order:
Complete 2,850cc kit engine: $1,000.
2,700-2,850 engine, starting with a closed case and 5th bearing in place, $1,300
2,700-2,850cc, built from the crank up with SPA Gen. II 5th bearing, $1,600
3.0L built from a closed case with 5th bearing in place; $1,600
3.0L built from the crank up with SPA Gen. II 5th bearing, $1,900
3.3L built from a closed case with 5th bearing in place; $1,900
Notes:
Labor on engine builds is taxed in Florida at 7.5% This rate also applies to any parts the builder buys while he is present in Florida.
Pricing based on heads arriving ready to “Bolt on”.
Crank up builds done with SPA Gen I bearings are an addition cost of $200
Supervised build costs are NOT REFUNABLE. At my discretion, I may allow allow them to be applied to a future build date , if I can find a builder to take the slot on short notice.
Other than 2,850 complete kit engines, It is the builders responsibility to make sure he has all the parts necessary to assemble his engine. The back of my manual has a checklist, and the parts required are detailed in the text. These parts must arrive clean, and ready to assemble. I will work to fix any gaps in the plan, but builders can not assume I have every part they will need, such as bearings and gaskets, is on hand. I am supervising Your build, prepare accordingly.
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FURTHER QUESTIONS: If you have questions, call or text me. The evenings after 8 pm is a good time. If you text in advance, it will help the productivity of the conversation.
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Davis Swartzendruber’s 3.3 going together for his Bearhawk LSA project.
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Brian Manlove’s 2,850 for his flying 601XL
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Rod bearings going in 2,850 cylinder assemblies.
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Earl Brown working on his 2,850
John McIntire running his 2,850 for his flying 601XL
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Going out to the local pub after the last day of the Supervised build.
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