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Belted Redrive:   1 | 2 |    Next...
 

Mockup of Pulley End Belted Reduction Drive Installation!

Click for larger view...

April 15, 2007
Front view of pulley end of VW Type 4 Engine Mockup showing the Reduction Drive setup. This setup is not like the VW Type 1... as the crankshaft nose is quite different... The Type 1 crankshaft has more nose for the drive pulley hub or prop hub grab on to. Plywood mockup is that of 5/8" thick 6061 T6 aluminum plate machined to the shape that it is in... This setup could be made to work with much machining and a lot of dimes... Then there would still be the danger of the prop coming off!

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April 15, 2007
Rear view flywheel end of the VW Type 4 engine showing a mockup of the Diehl Accessory Case rear mount. This case can be used on the Type 1 engine also. The starter and alternator is installed in the case here and a modified Type 4 flywheel. A Slick Magneto can be installed here also.

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April 15, 2007
This is a VW Type 4 engine with a Direct Drive pulley end configuration... and no Reduction Drive. This engine has a displacement of about 2600cc... with 103mm pistons/cylinders and a 78mm stroked crankshaft. This is a very powerfull engine... but there is one major problem! The nose of the crankshaft has to have major surgery in order to have the prop hub installed where it will not come off... keeps the pucker factor high to say the least!

 
The above Redrive Installation the Pulley End is not the preferred installation for the VW Type 4 engine! There is not enough crankshaft nose for the prop hub to be installed. It would have to machined to accept a drive pulley or a prop hub! The best setup for the VW Type 4 engine... is where the Redrive Unit is installed on the Flywheel End where it should! There has been to much focus on the Type 1 installation... wrong end again!
 

Mockup of a VW Type 4 engine, Flywheel End Belted Reduction Drive Installation!

Made a decision to go with the Flywheel Drive End Redrive instead of the Pulley End Redrive, just not practical... it was a no-brainer decision!
 
Click for larger view...

December 10, 2010
This a photo of a converted EA81 Subaru engine with a 2.10 drive ratio Belted Reduction Drive showing the Starter and Drive Pulley Lower Bearing Support assembly... which provides support to the crankshaft an structure to the unit...

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December 10, 2010
Pattern for the Belted Redrive Thrust Plate... designed for the VW Type 4 engine. This is different from the Soob engine and designed specifically for the VW Type 4 engine. Since the VW Type 1 engine shares the same flywheel housing as the VW Type 4 engine... this pattern will work for it also...

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December 10, 2010
These are the patterns for the Lower Bearing Support... which will be fabricated from some "C" channel and 1/4" 6061 T6 aluminum...

 
I purchased a set of construction drawings from Don Parham of RFI Int. just before he retired. He was the Belted reduction Drive guru and one of the many leaders in the Subaru engine conversions and Reduction Drive developments. His designs covered all Soob engines from the EA81 up to and including the EJ33 as well as the Mazda Rotary engine. What was unique about his designs was he included in his designs a Lower Drive Pulley Bearing Support! I was very fortunate to be able to acquire the actual construction drawings and build manuals from him at a very modest cost. It is to bad that Don retired because he produced some of the very first Soob Engine Conversions, along with the Redrive Parts and complete systems from the engine on up. If you needed a pulley or an individual part you could buy from him... what ever you needed! The Reduction Drive Industry lost a real pioneer to say the least.
 
Click for larger view...

December 10, 2010
Plywood Mockup of Thrust Plate showing the location of the Drive Pulley Lower Bearing Support... the location of the engine mount, starter location and various openings for the Upper and Lower pulleys...

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December 10, 2010
Thrust Plate and Rear Flywheel End view of VW Type 4 engine case...

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December 10, 2010
Side view mockup of the Thrust Plate mounted on the VW Type 4 engine case...

 
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December 12, 2010
Other side view mockup of the Thrust Plate mounted on the VW Type 4 engine case...

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December 12, 2010
Rear Flywheel end view mockup of the Thrust Plate mounted on the VW Type 4 engine case...

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December 12, 2010
VW Type 4 engine case view of the pulley end...

 
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December 13, 2010
VW Type 4 Engine case crossmember mount... from a VW bus! Can be used for the engine mount install...

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December 13, 2010
VW Type 4 engine case pulley end view... showing the location of the Bus Engine mount...

 

Belted Reduction Drive Parts!
 
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December 15, 2010
Thrust Plate mockup - To be made out of 5/8" 6061 T6 Aluminum... shows the Lower Bearing Support Assembly

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December 15, 2010
Redrive Raw material parts ready for machining...

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December 15, 2010
Drive Pulley Lower Bearing Support Parts - "C" Channel and 1/4" 6061 T6 Aluminum Plate, ready to finish...

 
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December 15, 2010
Redrive Prop Hub Bearings and Seals, Lower Drive Pulley Support Bearing and Seal and Stub Axle Shaft nuts...

 
 
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December 10, 2010
Lower Drive Pulley - 43 tooth... for Gates PowerGrip GT2 - width is 85mm. Made from Aircraft grade 6061-T6 aluminum and hard anodized. Designed to be used for 8mm Pitch Gates PowerGrip GT2 Belts...

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December 10, 2010
Upper Prop Pulley - 75 tooth... for Gates PowerGrip GT2 - width is 85mm. Made from Aircraft grade 6061-T6 aluminum and hard anodized. Designed to be used for 8mm Pitch GT Belts...

Click for larger view...

December 10, 2010
Gates PowerGrip GT2 Belt - 880mm x 8M - 85mm wide Belts. These belts have a Pitch of 8mm(110 tooth)...

 
Stock 8mm GT2 profiled Blower Sprockets from the Race car guys that are used on Supercharged engine... these are off the shelf types and only available for this 1.74 drive ratio... all that is needed is the the stub shafts and support flanges. A lot cheaper then having to machine out new Sprockets. The Sprockets can be acquired from Good Vibes Racing and are strictly used with the 8mm GT2 belts! The use of these size of Sprockets will provide a 1.74:1 reduction in prop speed... turning a 74" 3 bladed prop. This will allow the engine to develop maximum torque at an estimated 115HP to 125HP...

The Gates PowerGrip GT2 belt can be acquired from Royal Supply.Com. It should be noted that the Gates Powergrip GT2 Belts have the same tooth profile as the older Gates HTD belts that were used for years on the earliest redrives! The Powergrip GT2 belts are a lot stronger then the Gates older HTD belts. There is a newer Gates PowerGrip GT3 belt... but only available in Europe at this time and quite expensive!
 

 
Final Design of new Custom Redrive Sprockets for 1.79 Drive Ratio!

Made decision to go with new Custom CNC machined Sprockets... instead of the stock Blower Sprockets! The Blower Sprockets were the minimum and maximum sized of Sprockets that were available and the wrong size needed!
 
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July 15, 2011
CAD Drawing of newly redesigned 1.79 Redrive - 38 tooth Upper Sprocket and 68 tooth Upper Sprocket! This design will use an 800mm x 8M Gates PowerGrip GT2 belt from Royal Supply...

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September 16, 2011
Final Cog Belt Sprocket Design - New CNC Machined Cog Belt Sprockets... 38 tooth Lower and 68 tooth Upper, black anodized and ready for the Timken Bearings and Seal. Made by a fellow from South Africa... very good quality work!

Click for larger view...

September 16, 2011
This is another set of CNC Machined sprockets and parts - 38 tooth Lower and 80 tooth Upper made by the same machinist for a 2.10 drive ratio! These parts are for a Soob EJ22 Turbo!

 

 
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