Over the years, the Wrights seem to have made many changes in the engine: the bore was varied at different times, rod assembly methods were altered, and rod ends were changed from bronze to steel. Chenoweth states that on later engines an oil-control ring was added on the bottom of the piston, necessitating a considerable increase in the length of the cylinder barrel. This arrangement could not have been considered successful, as it apparently was applied to only a limited number of units and was not carried over to the later 6-cylinder engine model. There was much experimentation with cam shapes and most probably variations of these got into production.
With the crankcase, they did not go all the way to the modern two-piece form but instead retained the one-piece construction. Assembly was effected through the ends and a detachable plate was provided on one side for access to the interior. It is clear that they regarded this ability to get at the interior of the case without major disassembly as a valuable characteristic, and later featured it in their sales literature. They were apparently willing to accept the resultant weakening of the case and continued the construction through their last engine model. The integrally cast cylinder water jackets were abandoned and the top of the crankcase was machined flat to provide a mounting deck for individual cylinders. The use of aluminum alloy was continued, and the interior of the case was provided with strengthening webs of considerable thickness, together with supporting ribs. The cam shaft was supported directly in the case.
The individual cylinder design was of extreme simplicity, a single iron casting embodying everything except the water jacket. The valves seated directly on the cast-iron cylinder head and the guides and ports were all contained in an integral boss on top of the head. The exhaust valve location on the side of the engine opposite the pilot was a decided advantage over that of the 1903 design, where the exhaust was toward the pilot. A four-cornered flange near the bottom of the cylinder provided for fastening it to the crankcase, and a threaded hole in the top of the head received a vertical eyebolt which served as the rocker-arm support. The cylinder was machined all over; two flanges, one at the bottom and the other about two-thirds of the way down provided the surfaces against which the water jacket was shrunk. The jacket was an aluminum casting incorporating the necessary bosses and double shrunk on the barrel; that is, the jacket itself was shrunk on the cylinder-barrel flanges and then steel rings were shrunk on the ends of the jacket over the flanges. The jacket thickness was reduced by machining at the ends, making a semigroove into which the steel shrink rings fitted. These rings insured the maintenance of a tight joint despite the tendency of the aluminum jacket to expand away from the cast-iron barrel.
