I’ve flown a few hundred hours behind a VW conversions….Here’s my experience/opinions:
1. They’re inexpensive,
2. They require a cylinder head overhaul every 120h or so,
3. The electrics (ignition and alternator) can be problematic if not effectively cooled, (Read as: require blast tubes)
4. Whilst many VW users complain about cooling, with a great deal of baffle work and judicious removal of cylinder head casting flash, they can run cool,
5. The AeroVee 2.1 prop hub is heat shrunk and keyed onto a forged crankshaft. This has overcome early VW crankshaft problems, but if I were to ever own another, it would have the Revmaster style front bearing,
6. Almost all heads (EMPI et alia) develop shallow cracks between the valves,
7. Nikasil barrels are to be avoided at all costs. (Long story),
8. They need to have a minor mod to an oil gallery to ensure adequate lubrication of the front bearing, (It’s simple to effect),
9. They require a good deal of tinkering. Expect to remove the engine cowls
after every day’s flying. If you only remove cowls at annual intervals, don’t consider a VW.
10. The HP claims by the various suppliers are wildly optimistic. Mine ended up at 2297cc and only then did it come close to the 80HP claimed…60-70HP is more realistic for a 2180cc variant,
11. They’re simple engines, easy, fun and inexpensive to overhaul,
12. The “standard” AeroVee 2.1 crankcase is magnesium with reinforcement. Optional aluminium cases are impractically heavy.
13. No oil filter is fitted (or required) so 25h oil changes and valve adjustments are a good idea. (Always replace the cork rocker cover gasket or you’ll have issues with rockers contacting the covers),
14. Despite claims to the contrary, a well built VW won’t leak oil.
Now for some person opinions…
15. Every auto conversion engine is an orphan, irrespective of who the supplier is…The owner must consider themselves to be the manufacturer,
16. Auto-engines are not designed to run at high power settings indefinitely as required by aero-engines. (My car lopes down the highway doing 100kph at <1500 RPM.) The laws of thermodynamics cannot be avoided thus hot-rodding MUST impact reliability.
17. The Type 1 crankcase was originally designed to provide ~30HP, not 80+. Turbocharging a VW to attempt to extract 100HP is an exercise in hope over common sense.
My personal view is that it doesn’t make any sense for me to spend a single cent more on an aero-engine, UNTIL the instant the cheaper option gives a hint of trouble.
These days I don’t fly behind VW’s, but I won’t denigrate anyone who chooses to….It’s simply the level of informed risk that the owner/pilot is prepared to accept. If my circumstances changed and I was looking for a VW derivative, I’d lean toward a Limbach.