AEROCONVERSIONS ENGINE KITS, COMPONENTS & ACCESSORIES
AeroVee Engine Kits
The AeroVee 2.1 and AeroVee Turbo Engine Kit Packages are offered under AeroConversions product line of Sonex Aircraft LLC with experience in pioneering and innovating VW engine conversions since the early 1970's. AeroConversions product line includes high-quality powerplants, systems and parts for use in recreational aviation.
Both are offered as ENGINE KITS ONLY operating on AvGas (*) or Auto Fuel (**) including all hardware and documentation for assembly by the buyer. They are NOT PRE-ASSEMBLED ENGINES.
(*) AvGas Requirements: aviation gasoline 91/98 minimum grade conforming to ASTM D 910.
(**) Auto Fuel Requirements: automotive gasoline with a posted (R+M)/2 of 90 or greater conforming with ASTM D 4814.
AeroVee engines can run on either AVGAS (aviation gasoline 91/98 minimum grade conforming to ASTM D 910) or AUTO FUEL (automotive gasoline with a posted (R+M)/2 of 90 or greater conforming with ASTM D 4814). Manufactuer provides instructions to set-up a different compression ratio for AvGas (8.0:1) vs. Auto Fuel (7.0:1). The use of 100LL AvGas is recommended which maximizes the overhaul period and the available power output for the engine. Fuel consumption is 3.5 gph in cruise settings.
AeroVee 2.1 Engine Kit
The AEROCONVERSIONS AeroVee 2.1 is a complete non certified 2180 c.c. 80 HP VW conversion aero-engine engine kit package. It features dual ignition, using two spark plugs per cylinder and including four independent, solid-state ignition modules, all driven directly off the crankshaft/flywheel assembly. The AeroConversions secondary electronic ignition provides extremely reliable starting under the toughest conditions, while adding "dual-plus" ignition reliability by completing the AeroVee's quadruple-redundent ignition system. The modern AeroVee engine design has thousands of customer-flown fleet hours to its credit, with installations in a wide range of airframes. Engine can be assembled in approximately 12 hours, with the aid of an AeroVee Assembly and Installation Manual and an instructional DVD. The AeroVee DVD is available for purchase separate from the engine kit for those who wish to preview the project.
Recommended propellers to be used with AeroVee 2.1 are Sensenich Wood and Composite Fixed Pitch Propellers W54JV5L-44, W54JV5L-44G and WC56AJV5L-42G.
AeroVee Engine 2.1 Kit Features:
2180 cc 80hp Aero-Engine
Can be run on AvGas or Auto Fuel
Low-profile design provides for low-drag, streamlined cowl installations
"Dual-Plus" quadruple-redundant solid state ignition system
Robust Shrink-Fit Prop Hub with rounded keyway
Prop Hub/Crankshaft Assembly now available Pre-Assembled as an optional kit upgrade
Precision machined Universal Accessory Plate featuring widely-available motor mount bolt pattern
Standard 20 Amp Alternator
Light-weight aluminum Flywheel incorporates starter gear, 20 Amp alternator, and primary ignition magnet
Drive Bushings for optimum propeller to prop hub load distribution
3 piece Intake Manifold including billeted aluminum Intake Elbows and stainless steel "V" Tube
ACV-CO7S (32mm) AeroInjector included providing maximized power and optimized fuel economy in a simple, reliable carburetor design
Laser-cut, anodized Block-Off Plates included
Zinc-plated steel parts and hardware for improved corrosion resistance
All engine assembly hardware included
High-end aftermarket racing core parts, forged and nitrided wherever possible
Very low maintenance and overhaul costs
Detailed AeroVee Assembly and Installation Manual with companion DVD video
AeroVee-specific Sky-Tec "Flyweight" geared electric Starter
Many installation accessories available including exhaust and cooling systems
AeroVee Engine 2.1 Kit Technical Specifications:
Continuous Horsepower: 80 hp @ 3400 RPM
Bore: 92 mm
Stroke: 82 mm
Displacement: 2180 cc
Fuel: 100LL AvGas (Recommended) or Auto Fuel
Fuel Consumption: 3.5 gph in cruise settings
Compression Ratio: 8.0:1 for AvGas* - 7.0:1 for Auto Fuel*
Oil Capacity: 2.75 US Quarts
Oil Type: SAE Multigrade 20/50 Conventional or Semi-Synthetic: See AeroVee Manual
Firing Order: 1-4-3-2
Spark Plugs: Autolite MP4163 or equivalent
Carburetor: AeroInjector ACV-C07S
Starter: SkyTec Geared Starter
Alternator Output: 20 Amp
Weight: 160 lbs less oil and exhaust
Propeller Drive: 1:1
Prop Bolt Pattern: Qty 6, 5/16" diameter @ 4" Center
Prop Drive Bushings: 9/16" diameter x 7/16" long
Battery Required: 12v @ 20 Amp
Operating Limitations:
Idle RPM: 700-900
Cruise RPM: 3200 +/- 200
Maximum RPM: 4000
Oil Temp Min: 160 degrees F
Oil Temp Max: 230 degrees F
Oil Pressure Min: 10 psi
Oil Pressure Max: 100 psi
Oil Pressure @ Cruise: 40-50 psi
CHT @ Cruise: 350-375 degrees F
CHT @ Climb (5 min): 420 degrees F
CHT Max: 450 degrees F
EGT Max: 1400 degrees F
Available Options Sold Separately:
AeroVee Laser-Cut "Fence" Baffle Kit
2-into-1 Stainless AeroVee Exhaust
AeroVee DVD
AeroVee Turbo Engine Kit
The AeroConversions AeroVee Turbo is rated as a 100 horsepower engine at sea level, and yields significant aircraft performance enhancement. The AeroVee Turbo Engine Kit has all features of AeroVee Engine 2.1 Kit listed below for convenience and additionally the standard AeroVee-sized 32mm AeroInjector. It can operate on AvGas or Auto Fuel.
Low-profile design provides for low-drag, streamlined cowl installations
"Dual-Plus" quadruple-redundant solid state ignition system
Robust Shrink-Fit Prop Hub with rounded keyway
Prop Hub/Crankshaft Assembly now available Pre-Assembled as an optional kit upgrade
Precision machined Universal Accessory Plate featuring widely-available motor mount bolt pattern
Standard 20 Amp Alternator
Light-weight aluminum Flywheel incorporates starter gear, 20 Amp alternator, and primary ignition magnet
Drive Bushings for optimum propeller to prop hub load distribution
3 piece Intake Manifold including billeted aluminum Intake Elbows and stainless steel "V" Tube
ACV-CO7S (32mm) AeroInjector included providing maximized power and optimized fuel economy in a simple, reliable carburetor design
Laser-cut, anodized Block-Off Plates included
Zinc-plated steel parts and hardware for improved corrosion resistance
All engine assembly hardware included
High-end aftermarket racing core parts, forged and nitrided wherever possible
Unbeatably-low maintenance and overhaul costs
Detailed AeroVee Assembly and Installation Manual with companion DVD video
AeroVee-specific Sky-Tec "Flyweight" geared electric Starter
Many installation accessories available including exhaust and cooling systems
The AeroVee Turbo is a pull-through turbo arrangement utilizing the standard AeroVee-sized 32mm AeroInjector. As a "free-floating" system, boost is controlled only by throttle setting limited by a fixed waste gate and power still diminishes with gains in altitude, but losses are not nearly as-drastic as those with a normally-aspirated engine. Compared with the normally aspirated AeroVee (AeroVee 2.1) the AeroVee Turbo provides additional 20hp with an additional advantage: at higher altitude, performance will not degrade as rapidly as it does with normally aspirated engines. AeroVee Turbo makes it a great option for those operating at high field elevations or those wanting to cross over mountains! The AeroVee Turbo package increases climb performance 200-300 fpm with the Sonex Family aircraft and increases speed performance at altitude by approximately 25 mph.Just like AeroVee 2.1, the AeroVee Turbo can be installed in any suitable homebuilt aircraft design. The AeroVee Turbo is offered as a complete kit package, and upgrade packages are available to convert existing 80hp AeroVee 2.1 engines to the Turbo configuration.
Engine can be assembled with the aid of an AeroVee Assembly and Installation Manual and an instructional DVD. The AeroVee DVD is available for purchase separate from the engine kit for those who wish to preview the project.
Two Sensenich fixed-pitch propeller options are being offered for AeroVee Turbo installations:
54" diameter x 50" Sensenich propellers W54JV5L-50 and W54JV5L-50G intended for those wishing to maximize climb performance while still retaining a very-respectable TAS cruise capability,
56" diameter x 52" Sensenich propeller WC56FV5L-52G to maximize top-end speeds
AeroVee Turbo Specifications:
Horsepower: 100 hp @3400 RPM
Bore: 92 mm
Stroke: 82 mm
Displacement: 2180 cc
Compression Ratio:
8.0:1 for AvGas (91/98 minimum grade conforming to ASTM D 910),
7.0:1 for Auto Fuel with a posted (R+M)/2 of 90 or greater conforming with ASTM D 4814
Oil Capacity: 3 US Quarts
Oil Type: SAE Multigrade 20/50 Semi-Synthetic
Firing Order: 1-4-3-2
Spark Plugs: Autolite MP4163 or equivalent
Carburetor: AeroInjector ACV-C07S
Starter: SkyTec Geared Starter
Alternator Output: 20 Amp
Weight: 185 lbs less oil
Propeller Drive: 1:1
Prop Bolt Pattern: Qty 6, 5/16" diameter @ 4" Center
Prop Drive Bushings: 9/16" diameter x 7/16" long
Battery Required: 12v @ 20 Amp
AeroVee Turbo Operating Limitations:
Max. Continuous Power: 35 in Hg MAP
Max. Power (2 minuites): 40 in Hg MAP
Idle RPM: 700-900
Cruise RPM: 3200-3400
Max. RPM: 4000
Oil Temp Min: 100 degrees F
Oil Temp Max: 230 degrees F
Oil Pressure Min: 10 psi
Oil Pressure Max: 100 psi
Oil Pressure @ Cruise: 40-50 psi
CHT @ Cruise: 350-375 degrees F
CHT @ Climb (5 min): 420 degrees F
CHT Max: 450 degrees F
EGT Max: 1400 degrees F
Recommended Options Sold Separately:
- ACV-C10-30 Air Filter Assembly,
- ACV-S03-01 Oil Separator,
- ACV-P01-106 Top-Mount Oil cooler mount with hardware,
- Assembled Crankshaft option,
- Cooling Baffle Kits (same between Turbo and normally aspirated AeroVee installations),
- AeroConversions CHT Probes
AEROCONVERSIONS Engine Components & Accessories
AeroInjector
The AeroInjector (formerly known as AeroCarb) achieves outstanding performance versatility. Its construction is based on only two moving parts without float bowls or secondary jets to complicate operation. A fine adjustment metering needle provides clean burning, smooth running, outstanding response, and fuel economy. Spigot or flange mounts easily adapt to popular aircraft and auto conversion engines. AeroInjector's intake design accepts air filters or carb heat ducts.
AeroInjectors have been successfully installed in different aircraft engines, from Continentals and Lycomings to Chevy's and Suzuki's. It is included as standard with all AeroVee engines.
The AeroInjector is available in 2 sizes and with any combination of spigot or flange intake manifold and air box/air filter mounts, serving engines producing 30-125 horsepower. It can be fitted with flange mount and optional Intake Flange Adapter (ACV-C10-10) to bolt the AeroInjector directly to the fresh air intake box or carb heat box.The ACV-C10-10 Intake Flange Adapter fits directly onto the standard AeroCarb/AeroInjector intake bell and is a 3.125" (3 1/8") square flange with four 0.1875" (3/16") mounting pilot holes spaced 2.5" on-center.
*Caution: do not provide ram air intake to the AeroCarb/AeroInjector as ram air velocities at different airspeeds will effect mixture.
**Carb heat is not required with the AeroCarb/AeroInjector, however, some countries require the installation of carb heat, and some retrofit installations may be greatly simplified by retaining the carb heat box.
2-into-1 Stainless AeroVee Exhaust
The 2-into-1 Stainless AeroVee Exhaust provides 2-into-1 collection on each side, using two headers and two slip-on extensions, made from 304 stainless steel. Installations of the AeroVee Exhaust on aircraft other than Sonex aircraft may use custom slip-on pipes to fit virtually any installation, or trim/re-bend the provided extension pipes to suit. Exhaust ships with intstallation hardware and instructions.
For those who cannot utilize the 2-into-1 Stainless AeroVee Exhaust, AeroConversions offers laser-cut 304 stainless steel, 0.190" thick, AeroVee Exhaust Flanges for use in fabrication of custom VW exhausts.
AeroVee Top Mount Oil Cooler
Type I VW oil cooler for top mount installation on the normally aspirated AeroVee 2.1 or AeroVee Turbo Engine. The normally aspirated AeroVee 80hp engine may optionally be configured for a remote oil cooler. The remote oil cooler is specified in the AeroVee Engine Manual by vendor and part number, but is not sold by AeroConversions. Remote oil cooler installation also requires installation of a 2-stage oil pump.
Oil Cooler Top Mount Plate allows for mounting a standard VW oil cooler to the top of the AeroVee Engine while reversing the oil cooler's orientation to not sit over the cylinders, and moving the cooler aft to allow for streamlined cowl installations. The AeroVee Oil Cooler Top Mount Plate is specifically intended for installation in current Sonex Aircraft models, but also may be applicable to other non-Sonex AeroVee Engine installations. Oil Cooler Top Mount Plate is provided with AeroVee Engine or AeroVee Turbo Engine if ordered with Top Mount Oil Cooler configuration.
Oil Separator
The new and improved AeroConversions Oil Separator features larger volume and enhanced aerobatic capability. It is a high-quality welded and powder-coated aluminum assembly designed to save oil vs. direct overboard crankcase breathers in normal flight operations, and an effective solution to keep the aircraft bottom surface clean. The AeroConversions Oil Separator has provisions for both an overboard vapor breather/dump tube, as well as optional installation of an oil return line to the engine's oil sump, perfect for use with the AeroConversions Machined Oil Sump Plate. In addition, the AeroConversions Oil Separator features an extra-high-volume design and a ball-bearing gravity changeover valve offering enhanced inverted flight performance in entry-level aerobatic aircraft. The Oil Separator allows oil to be retained and returned to the engine during short-duration inverted and negative G maneuvers. It ships with comprehensive installation instructions suitable for a wide-range of engine installations. AN fittings, hoses & clamps not included.
Product Specifications:
Total Oil Separator volume: 40 oz.
Volume held before overboard dump if no oil return line is installed: 33 oz.
Diameter: 4 inches
Total Height: 7.5 inches.
Breather Input and Oil Drain/Return Ports: 1/2-10 NPT.
Vapor Port Out: 5/8" OD tube.
The ACV-P06-75 Mini Sump with Filter Kit has an oil return fitting machined in to allow for an oil return line from an oil separator. This oil filter is lower-mounted and replaces the ACV-P01-53 oil change kit and/or the ACV-P02-20 oil sump plate. Suitable for those desiring a permanent oil filter for their engine. Included as standard equipment with all AeroVee Turbo kits. Available for AeroVee 80hp, but not required. Includes additional 1/4 NPT threaded hole provided for oil return line from an oil separator. Includes 1/4 NPT plug for use if no oil return line is installed.
Air Filter Assembly
AeroConversions Air Filter Assembly may be fitted directly or remotely to the intake bell of the AeroConversions AeroCarb/AeroInjector which is supplied with AeroVee Engine Kit and uses readily-available automotive-type 4" diameter replacement filter elements. Ships with 1 air filter element.
Throttle Quadrants
AeroConversions Throttle Quadrants are designed to work with the AeroConversions AeroCarb/AeroInjector which is supplied with AeroVee Engine Kit and other carburetors equipped for reversing pull-throttle actuation. They consist attractive, simple and easy to install solutions offering the sport pilot positive and precise throttle control at a competitive price.Left-Hand and Right-Hand Throttle Quadrants are available to provide dual, slaved throttle control on both cockpit walls with one engine control output from the LH quadrant.
AeroConversions Throttle Quadrant ST is designed for use in a center-cockpit control column. The Throttle Quadrant ST features a placarded backing plate, angled control arm for instrument panel clearance, and dual control grips for authoritative control from both sides of the cockpit.
CHT Probes
AeroConversions CHT probes are made to be attached to cylinder heads independently. For AeroVee, or any other VW head engines, the AeroConversions CHT Probe is screwed into the cylinder head with a small self-tapping screw. AeroConversions CHT Probes are sold in sets of 2 probes, available in either K-Type or J-Type, depending upon your instrumentation's requirements. Thermocouple wire length: 48 inches.
Fence Baffle Kit
The Fence Baffle Kit is laser-cut to fit every nook and cranny of the VW engine. The fences are sized and contoured for Sonex Aircraft installations, however, the fences may be trimmed or extended by customers as-needed to fit other cowl profiles.
Spinners
AeroConversions new hollow-center spinners are approximately half the weight of earlier AeroConversions spinners. Spinner/Crush Plate is machined from solid 6061-T6 aluminum billet.
Great for higher RPM engines that tend to shed traditional sheet metal or fiberglass spinners. Suitable for AeroVee, Jabiru 2200, Rotax and UL Power (standard flange) Prop Hub Bolt Pattern with 5/16" dia. bolt holes. Also availalable to fit SAE-1 prop hub bolt pattern with 3/8" dia. bolt holes, used on Jabiru 3300 and many other engines. Weights: AeroVee/2200/Rotax/UL Power (standard flange) - 1lb, 4.5oz; SAE-1 (3300) - 1lb, 14oz.
