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Copyright © 2011 Bronson Engineering Company.-All Rights Reserved Privacy Policy Terms of Use Made By Serif
Airframe
Since the airframe proper is derived from parts of a proprietary design, I cannot represent or draw any of their
details in my narrative. Of course, buying a manufactured kit (or existing assembled aircraft) allows the owner
access to factory replacement parts. Even though inadvisable, many owners modify their airplanes, sometimes
in radical ways. While this does not ban them as a legal owner from buying factory replacement parts it does
void liability regarding the original aircraft manufacturer and the aircraft built becomes totally one,s own creation.
In my case, I came by a Kolb Twinstar, which had wrapped itself around a tractor parked near the runway during
a heavily loaded crosswind takeoff attempt. The aircraft was totally destroyed beyond repair, but all of the aircraft
steel components survived without damage. I bought about $370 of assorted aircraft aluminum and using a few of
the damaged aluminum parts as templates completely built new wings & flying surfaces to the covering stage in
a scant ten days. Covering & painting took another ten days and I had everything except for the pusher pod.
Given cooling considerations, I elected to do careful weight & balance calculations and mount my completed
½ Volkswagen on the front of a pod of my own design & configuration. The wings, tail boom & tail feathers
all attached in identical relation to my pod as a conventional Kolb Firestar (I had shortened the Twinstar
wingspan to Firestar dimensions to meet FAA Part 103 dry-weight requirements of 254 pounds.
My pod design required $187 worth of aircraft steel tubing to construct and I did all the gas welding and joint
normalization with my old acetylene torch. The covering material & related Stits System paints & adhesives
were bought for $300 from a guy who gave up on his own project.
At some point, I plan to document the construction of my pod & include step by step information for interested
people to study on their own. As with all my How I Did It narratives, they are for study & personal amusement
only and beyond being actual and repeatable information on how I build things, they are not intended to be
used for plans. Anyone is free to experiment duplicating my results, but I do not intend for anyone to actually
fly or use something I choose to risk my own neck in.
details in my narrative. Of course, buying a manufactured kit (or existing assembled aircraft) allows the owner
access to factory replacement parts. Even though inadvisable, many owners modify their airplanes, sometimes
in radical ways. While this does not ban them as a legal owner from buying factory replacement parts it does
void liability regarding the original aircraft manufacturer and the aircraft built becomes totally one,s own creation.
In my case, I came by a Kolb Twinstar, which had wrapped itself around a tractor parked near the runway during
a heavily loaded crosswind takeoff attempt. The aircraft was totally destroyed beyond repair, but all of the aircraft
steel components survived without damage. I bought about $370 of assorted aircraft aluminum and using a few of
the damaged aluminum parts as templates completely built new wings & flying surfaces to the covering stage in
a scant ten days. Covering & painting took another ten days and I had everything except for the pusher pod.
Given cooling considerations, I elected to do careful weight & balance calculations and mount my completed
½ Volkswagen on the front of a pod of my own design & configuration. The wings, tail boom & tail feathers
all attached in identical relation to my pod as a conventional Kolb Firestar (I had shortened the Twinstar
wingspan to Firestar dimensions to meet FAA Part 103 dry-
My pod design required $187 worth of aircraft steel tubing to construct and I did all the gas welding and joint
normalization with my old acetylene torch. The covering material & related Stits System paints & adhesives
were bought for $300 from a guy who gave up on his own project.
At some point, I plan to document the construction of my pod & include step by step information for interested
people to study on their own. As with all my How I Did It narratives, they are for study & personal amusement
only and beyond being actual and repeatable information on how I build things, they are not intended to be
used for plans. Anyone is free to experiment duplicating my results, but I do not intend for anyone to actually
fly or use something I choose to risk my own neck in.
Engine
Since 1994, I have been selling a 61 page illustrated step-by-step narrative on How I Built the Smooth-Running
½ Volkswagen Engine that powers my Fourstar. This narrative is completely adequate to duplicate my results,
but was done on an early word processor, with hand drawn illustrations. I am currently re-mastering the entire
narrative on my computer with crisp computer generated graphic illustrations. If you cannot wait for my new
release, you can simply buy a copy of the original. I serial number and record each buyer so if you buy the
earlier narrative, keep an eye on this site for the computer generated release and I will mail it to you at no
additional charge.
but was done on an early word processor, with hand drawn illustrations. I am currently re-
release, you can simply buy a copy of the original. I serial number and record each buyer so if you buy the
earlier narrative, keep an eye on this site for the computer generated release and I will mail it to you at no
additional charge.
Engine Narrative Ordering Information
Include a brief letter with your personal check or money order in the amount of $75, which also covers
postage in the US. Overseas buyers add $5 for postage. Include your name, address & phone number
(email address too if you have one). US Mail usually will arrive in ten-twelve working days.
Send your letter to: Bill Bronson-2540 Hillcrest Drive-High Ridge Missouri 63049 USA
( bill-bronson@sbcglobal.net )
postage in the US. Overseas buyers add $5 for postage. Include your name, address & phone number
(email address too if you have one). US Mail usually will arrive in ten-
Send your letter to: Bill Bronson-
Home Things that Fly Airframe & Engine
Direct drive Airplane Engines are not car engines. With car engines,
those of us who build them know all kinds of tricks to coax extra
horsepower & RPM out of them. These hot rod strategies work against
us when we connect a car engine to a propeller. We must coax ourselves
to think agricultural engine not hot rod engine. An old 8N Ford tractor will
pull a single blade plow. If we mill the head, put in bigger valves & a hot
camshaft, it will idle rough, overheat and smother itself when the plow
digs in.
My strategy is to use the smallest VW valves & camshaft, Zenith
carburetor, lowest VW compression ratio, 92 mm pistons and a Scat
stroked crankshaft ((if you can afford it). I also balance this engine
differently as butter-smooth operation and tick-over dependable idle is
demanded by ultralight airframes and safe landings. Also, these
precautions allow my engine to run at very low temperatures with
those of us who build them know all kinds of tricks to coax extra
horsepower & RPM out of them. These hot rod strategies work against
us when we connect a car engine to a propeller. We must coax ourselves
to think agricultural engine not hot rod engine. An old 8N Ford tractor will
pull a single blade plow. If we mill the head, put in bigger valves & a hot
camshaft, it will idle rough, overheat and smother itself when the plow
digs in.
My strategy is to use the smallest VW valves & camshaft, Zenith
carburetor, lowest VW compression ratio, 92 mm pistons and a Scat
stroked crankshaft ((if you can afford it). I also balance this engine
differently as butter-
precautions allow my engine to run at very low temperatures with
1.27 MPG fuel consumption @ 40 MPH (3500 RPM max on propeller).