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 Project Back to '91!

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vietnam
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My Ride(s) : 07 Golf, t25 devon
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PostSubject: Re: Project Back to '91!   Mon Nov 12, 2012 12:14 am

Nice to see some reengineering rather than just replacing it all Smile
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clockwork
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My Ride(s) : 63 Square, 71 Fastback, 72notch,71 Bay, 14 A5 3.0 S-line Sportback
Registration date : 2009-08-09

PostSubject: Re: Project Back to '91!   Mon Nov 12, 2012 5:25 am

Good work Al..coming along nicely Very Happy
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Big_Al
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My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Sat Mar 16, 2013 10:27 pm

Bit more done..

Combustion chamber reshaped and cc'd



Spark plug hole drilled



Valves all fitted



Now using a 37 mm inlet and 33 mm exhaust, I kept the valves on the small size to increase velocity at lower rpms, should help keep the power band towards the middle,

Also, because I'm using 36mm venturis in the carbs, it keeps the flow smooth!
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Gungemyster
a.k.a. Clunge, The Club Deviant
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Male Number of posts : 12646
Age : 45
Location : Weston-super-mud
My Ride(s) : 1975 south african imported beetle two tone grey, 1997 Red T4 shag palace
Registration date : 2008-03-28

PostSubject: Re: Project Back to '91!   Sat Mar 16, 2013 11:48 pm

great work sir, I would be lost when it comes to the finer detail like this!
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Big_Al
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Male Number of posts : 3567
Age : 44
Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Sun Mar 17, 2013 8:49 am

In all honesty, I would have been better off buying new heads, for the cost of new valves, springs, retainers, seats, all the machining work and the time to reshape it all,

But that's not the point!!
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vietnam
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Male Number of posts : 1671
Age : 28
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

PostSubject: Re: Project Back to '91!   Sun Mar 17, 2013 10:07 am

Must be a lot more satisfying to have been able to do work like this than just swap bits though?
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Big_Al
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My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Sun Mar 17, 2013 11:17 am

It is I suppose, if they were stock heads to start off with I would have binned them, but they have been extensively worked, so it made a bit more sense to save them.

Can't wait to get driving again!
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Big_Al
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Male Number of posts : 3567
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Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Mon May 13, 2013 6:19 am

Right, while I'm waiting for a few bits, I thought I would repair the dent in the front wing where the half inch air gun fell off the shelf!



The dent knocked out pretty well with my new panel beating kit!

Left a bit of an indentation though



Bit of rubbing down



Light smothering with filler



Rubbed down



Primed



Top coat is done, but I'll take more pics later when I flat and polish.
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Big_Al
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Male Number of posts : 3567
Age : 44
Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Wed May 15, 2013 7:24 pm

Replaced the engine mounts with the polyurethane ones I bought at Big Bang,



After speaking to Nomates, I think I'll replace the bolts the front mount came with because I don't think they are long enough.

Rear ones fit lush though!



Time to start getting the engine together now!
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Big_Al
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Male Number of posts : 3567
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Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Thu May 16, 2013 8:07 pm

Woo Hoo! I now have a complete longblock!




Just got to start bolting all the bits and pieces back on, hopefully I'll have it in the car by the end if Sunday!
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Mr Scoops
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My Ride(s) : 1971 Patinaed Early Bay: 2006 Mondeo ST (I'm so ashamed.....)
Registration date : 2006-08-19

PostSubject: Re: Project Back to '91!   Thu May 16, 2013 9:02 pm

Good work Al, looking forward to seeing your Bug back on the road.

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vietnam
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Male Number of posts : 1671
Age : 28
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

PostSubject: Re: Project Back to '91!   Thu May 16, 2013 9:33 pm

Sweet! It's been a long time coming Wink
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Big_Al
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Male Number of posts : 3567
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Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Sun May 19, 2013 6:38 pm

Moved the engine to the rear of the car using Charlie's skateboard to move it, started assembly of ancillary parts.



Got more tinware and the exhaust fitted too, I cleaned the j-tubes up and sprayed them with high temp paint.



Just the fanshroud and clutch assembly to fit to the motor and it can get bolted back in, I'm going to grind down the engine mount studs a bit first though to avoid fouling the flywheel, then I'm going to have to rethink my oil filter location, I'm not happy with the length of pipe to it.
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tango_van
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My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Project Back to '91!   Sun May 19, 2013 8:03 pm

Looking good Al!
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dubberatlast
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PostSubject: Re: Project Back to '91!   Sun May 19, 2013 9:33 pm

good work mate.
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Gungemyster
a.k.a. Clunge, The Club Deviant
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Male Number of posts : 12646
Age : 45
Location : Weston-super-mud
My Ride(s) : 1975 south african imported beetle two tone grey, 1997 Red T4 shag palace
Registration date : 2008-03-28

PostSubject: Re: Project Back to '91!   Sun May 19, 2013 10:51 pm

Well done mate
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Big_Al
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Male Number of posts : 3567
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My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Wed May 29, 2013 4:44 pm

Half day today, so I cracked on with some jobs, got the bolts in the nosecone mount replaced, replaced the release bearing and ground the studs of the rear mounts like I was hoping.

Fitted the rest of the tinware too, with the help of a rubber mallet.



Engine, say hello to gearbox, long time no see!



10 minutes later!!



Like a glove!
I re-plumbed the oil cooler/stat pipes so they run correctly, I need to fab a bracket for the oil filter to mount on the exhaust studs I made a template out of cardboard and I'll have a go at making it at work tomorrow.
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nomates
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Male Number of posts : 18609
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My Ride(s) : 1967 fridolin and 1966 (award winning-and yea i am being gay) ghia and 1960 bubble car
Registration date : 2006-11-19

PostSubject: Re: Project Back to '91!   Wed May 29, 2013 6:30 pm

nice one dude ......good job
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Mr Scoops
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Male Number of posts : 37844
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Location : Weston Super Dooper
My Ride(s) : 1971 Patinaed Early Bay: 2006 Mondeo ST (I'm so ashamed.....)
Registration date : 2006-08-19

PostSubject: Re: Project Back to '91!   Wed May 29, 2013 9:07 pm

Back on the road soon then? You bringing it up to Bristol?

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Big_Al
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Male Number of posts : 3567
Age : 44
Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Wed May 29, 2013 9:24 pm

I was hoping to have it ready for Bristol, but it's not going to be, I still have to get the bloody thing running right, replace a couple of ball joint boots, get it MOT'd and taxed.
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Mr Scoops
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Male Number of posts : 37844
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My Ride(s) : 1971 Patinaed Early Bay: 2006 Mondeo ST (I'm so ashamed.....)
Registration date : 2006-08-19

PostSubject: Re: Project Back to '91!   Wed May 29, 2013 9:33 pm

Bummer

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Big_Al
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Male Number of posts : 3567
Age : 44
Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Thu May 30, 2013 1:06 pm

Bracket fabbed,

From this



To this



I'll offer it up to the car and get the filter bracket mounted correctly before I take it off and spray it up.
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nomates
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Registration date : 2006-11-19

PostSubject: Re: Project Back to '91!   Thu May 30, 2013 3:56 pm

what filter ? ........looks too thin for a bracket to me ......got some 2mm steel here dude if you want a cut off
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Big_Al
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Male Number of posts : 3567
Age : 44
Location : Under The Thumb.
My Ride(s) : 1970 looker, 2009 T5 'The Night Fury!', 2006 Challenger 3 tank (wife's)!
Registration date : 2008-02-05

PostSubject: Re: Project Back to '91!   Thu May 30, 2013 4:37 pm

It's 2mm galv steel, photo is a bit shit, it doesn't show the mounting holes and bend.
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nomates
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Male Number of posts : 18609
Age : 44
Location : weston-s-mare
My Ride(s) : 1967 fridolin and 1966 (award winning-and yea i am being gay) ghia and 1960 bubble car
Registration date : 2006-11-19

PostSubject: Re: Project Back to '91!   Thu May 30, 2013 6:24 pm

cool
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