Great Plains Aircraft
2003 Beetle Flyer		 Page 2

Box Baffling Looks Pretty - But!
One of the items of continuous debate over the last 30 years seems to do with the correct way to make the baffling around the cylinder heads when using an enclosed cowling. One school (of thought) wants you to make a baffling that only goes to the outside edge of the cylinder heads fins, as shown Below in Photo A.
Box Baffling
Photo A
The other method (we prefer and sell plans for) shows how to attach the baffling outside the valve guide fined area, as shown Below in Photo B. Both methods work, but we believe that the method in Photo B to be the better of the two.
Full Pressure Cowling
Photo B
Look for a moment at the stock VW cooling tin that goes on the VW engine installed in a car. The cooling tin does not stop at the edge of the cylinder head fins. Instead it extends out to the outer edge of the finned area of the head as shown in Photo C (to the right). This allows for cooling of the exhaust port, intake port and valve guide area. Years ago Ed Sterba had box baffling that went to the end of the cylinder head fins only, on his Sonerai II. In an effort to lower the cylinder head temperature, he made a box that went under the head and blew air up. The temperature dropped an amazing 30 degrees F. Stock VW Cooling
Stock VW Cooling

Cylinder Head Temperature Thermocoupler (Sender) Location
Although it seems obvious to install the cylinder head temperature sender underneath a spark plug as the sender is 14mm, this is really not representative of the average temperature of the cylinder head. This is the hottest location however! In a test of 10 locations on a VW cylinder head, that included under the spark plugs and under each one of the cylinder head stud washers, the hottest temperature was under the spark plug. In fact, reading the temperature under the plug was a little better than 150 degrees F hotter than the coolest place on the head, which was under the two center cylinder head stud washers inside the valve cover.
We find that many builders that complain of high cylinder head temperatures really don't have a high cylinder head temperature average. Recently a builder called trying to cool down a 450 degrees F head. The engine runs fine he said. "Good oil temp, good oil pressure and the EGT was 1250". But he just could not get the head to run any cooler. He was measuring the temperature under the spark plug. After a brief chat he moved the probe around, measuring temperatures on the head. He installed it finally under a cylinder head temperature studs washer that was on top of the head behind the intake manifold where he found his average temperature. His gauge now reads about 325 degrees F - his average. Cylinder Head Probe
If you've ever looked at the cylinder head temperature probe on a VW Beetle equipped with one, the probe is installed in a cylinder head boss that is just above the rockerarm cavity, not under a spark plug (see photo). The cylinder head temperature runs about 100 degrees F cooler at this location than under a cylinder head stud washer and about 200 degrees F cooler than under a spark plug. The hole in the white circle is for a fuel injection enrichment temperature probe.


IN THIS ISSUE OF
THE BEETLE FLYER:
Sun & Fun Update Page 1
New Product Catalog Page 1
New Type 1 Assembly Manual Page 1
Technical Solutions Page 2
Leading Edge Tape, Oil Coolers,
& New Rockerarms		 Page 4
Beetle Flyer Specials! Page 3

Great Plains Aircraft annual Holiday Beetle Flyer Sale!

Beetle Flyer sale prices are effective December 17, 2003 through January 16, 2004 ONLY.

Order toll free at 1 800 922 6507 US ONLY or (402 493 6507), fax 402 493 3846, or on-line at www.gpasc.com. Don't call us after the sale dates and request the sale price, it won't happen! Order it now! Individual offers may not be combined with other sale items to further reduce the cost. Sale prices do not include freight.

Remember: Beetle Flyer sale items can ALSO be purchased on On-line using our Shopping Cart at: www.gpasc.com

1. Order any Long Block Front Drive Engine Kit with one or more combinations of Accessory Packages 1, 2, 3, 4, 5, or 6. Deduct 10% off the total price. Applies to both U-Assemble Kit or Factory Built. Requires $500 deposit.

2. Order a Reduction Drive, Reduction Drive Long Block Engine Kit, and Accessory Package (combination of 1, 2, 3 or 6) and take 10% off the total price. Applies to both U-Assemble Kit or Factory Built. Requires a $500 deposit.

3. Single Mag Drive Kit. Retail is $239.95, BF sale priced at $199.95.

4. Spark Plug Adapters retail for $94.95. BF sale priced at $89.95, plus freight.

5. Slick 4316 Magneto. Buy the Magneto for $549.95, and receive the harness for FREE. This is a $111.95 value.

6. Great Plains Hydraulic Brake Retrofit Kit. Retails for $289.95. BF sale priced for $249.95. Fits Azusa 5" or 6" wheels.

7. Wheel and Hydraulic Brake Kit. Kit includes 2 each: 5" wheels, heel/toe master cylinders, brake line kits, 410 x 350 tires and tubes and the complete hydraulic brake kit, a $538.60 value. BF priced at $457.90.

8. Order either a Shrink Fit or Standard Tapered Prop Hub. List price is $144.95, BF sale priced at $119.95.

9. Force One Prop Hub & Main Bearing Kit. List price is $332.85 (Type 1). Get the best prop hub and bearing available for $289.95. Does not include cost of machine work to crank ($75.00).

10. Take 10% off any of these SONERAI Parts: ailerons, landing gear, taper pins, tailspring, tail wheel caster, spar kit, or rib kit.

11. Take 10% off any of these items IN STOCK ONLY: Sonerai II Canopy, Sonerai I Cowling, Sonerai II Cowling.

12. Order any 3 "How To Books" and receive the Type 1 Assembly Manual FREE.

13. Take 10% off our Low Height Secondary Ignition System and machine work to your heads. (Note: If you don't have the heads, you can buy the stock or premium heads from us too, for a 10% discount!)

14. Take 10% off the purchase of 5 each VDO or UMA instruments.

15. Piston & Cylinder kits: 92 X 82 or 92 X 69, retail at $219.95. BF sale priced at $189.95.

16. The Bosch 009 Ignition Kit with the 90 Distributor cap retails for $164.50. BF sale for $139.82!

17. Complete Diehl Accessory Case Kit (bottom mount accessory case, 4D flywheel, alternator, mag drive and starter) retails for $679.70. BF sale for $605.70. Add $15.00 for top mount starter position or 8D flywheel.

18. Deduct 15% off any complete 10" or 12" Spinner Set.

19. Premium dual port 042 cylinder heads, machined for 92 or 94 bore retail at $469.40 for the pair. BF Special for $398.95!

20. Great Plains X-Casting Kit. Includes X-Casting, flywheel end piece, alternator, mag drive kit, Lycoming bushings and hardware. A $499.80 value. BF priced $439.00.

21. 69mm crank with Shrink Fit Prop Hub kit, retails for $279.95. Sale priced at $245.95. Or buy a 69mm crank, 3 Prop Hub and seal, and tapering to the crank. Retails at $361.85. BF sale priced at $299.85.

22. Compu-Fire Ignition System and 009 Distributor. List price is $304.90. BF sale priced at $285.35.

23. Take 10% off either of our 1821 or 1617 carburetors.

24. Type 1 Force One Prop Hub Complete Kit and 82mm crank tapered. List price of $1157.80. BF sale priced at $1045.00.

25. Scrap 2024T3 .025" Aluminum for Baffling! Various sizes, but plenty to baffle your aircraft! $20.00.