71 Early Bay (formerly known as Superdry)

I dot punch stuff, but that's a habit from work. Looking good though dude! Back running before the end of summer?

I really do want it back on the road now so yes, aiming for the end of the Summer

race ya to get it back on the road

You win!

Will is away this week so I plan to crack on again.
I'll get the other valves lapped in. I've just ordered a new set of collets so then I can go and request the assistance of Dr Nomates to reinstall my springs, give the heads a proper clean and then leak check the heads.

New pulley

http://www.thesamba.com/vw/classifieds/detail.php?id=1788823

Tried to use my own valve spring compressor to temporarily fit the valves but it isn't made for aircooled VW heads so I think I'll order a pukka one for the job.
A bit gutted as I wanted to get more done this evening but Ho Hom.
Another little thing I did though was to check the thermostat.
At least some good news on this

what did you use a hairdryer?

nomates wrote:

what did you use a hairdryer?

Yeah, I wanted to know what it felt like to use one again!

Just popped out to the garage for a quick trial fit of the valves.






As you can see I got the valves back in using my new tool and then filled the combustion chamber with white spirit to check for leaks.

And there was!





Pissed out of Number 3 exhaust and a dribble through Number 4 inlet.

I'll pop them out and give them another lap and try again.

I've got to try and find my motivation because at the moment I'm thinking I may as well get the engine in and sell it as I don't feel that fussed that I don't have it to drive. Fingers crossed I'll feel a bit differently once I make a bit of progress again.......

i haven't touched my beetle in ages dude but i know when i do ill love it again, fix it all up nice , get to some shows in it and then if you still don't enjoy then sell. don't rush into anything. if you need a hand ill pop over and help you finish it.

it will takes to lap in valves by hand, use a battery drill

Road Rage wrote:

it will takes to lap in valves by hand, use a battery drill

Something else I need to get then......

Yes. It takes ages.. I did all mine by hand... Took forever and did each on a course then fine grinding paste.. Just make sure u clean it out lots!!!!

Also if you're planning to cut the corner and drill...Be careful using a drill as you'll need low revs, oil the guides and be careful not to get them too hot. it can put an uneven lap in as u are not able to put an even pressure on the valve. Also u have to keep alternating the rotation...

Set yourself a deadline to complete it by. Something you can't get out of.... Then you will put in the hours

So. I popped to the Engine Gods house earlier and borrowed the engine stand again.
Got the engine lifted up and bolted on.
I thought I'd pop the fuel pump rod and bakelite 'roofer' off. In doing so, the bloody bakelite thing snapped.
Fuck it!!





I tried to get the bloody thing out with a pair of pliers but it wasn't budging.



I tried to wind a coachscrew in to it to see if I could pull it out that way


But all that happened was it started to break up.

Not sure sure if I am going to have to split the case to get it out, or just leave it in there.

Whilst I was out there I thought I'd have a little play with some more of these.


Got the two number 2 valves done so slipped them in with their springs etc and did a leak test.



Initially it looked fine


But then it was apparent that the exhaust valve wasn't sealing.




BALLS!!!
I'll pop them back out and give them a bit more of spinny spinny with the grinding paste, then have a pop on to Number 1.

So the question is, shall I just put the blanking plate on and ignore it, or shall I split the case and get it out.
I can check the crank etc then I suppose if I split it......although I'll have to buy a case splitter.

It'll have to come out, if it breaks, you'll have loads of bits flying around your engine.

Have you thought about running a tap into it? Then using a washer on the top and a bolt of a suitable length to pull it out?

I did think that Al, it's pretty fragile and I think it will just break up.
I think the best thing to do is split the case, I can check the crank etc then

Mine did just the same when I tried to remove, snapped in the same place, no matter what I did to it (apart from breaking it up or splitting the case) I just couldn't get it out. My one advantage is that I don't have to replace it as I'm running a electric fuel pump. My mate was visiting (who ran a VW service department) says leave it in, if it breaks down, it's bakealite? and should get crushed up, then you should change the oil. I was concerned but he said it should be ok!!!! Luckily it's still stuck there at the moment. I also run a spin on filter, which hopefully will stop the contamination reaching the bearings. The engine has ran like that since April, with the lower part stuck.

I'm going to run an electric pump but have decided to split the case to get it out. Don't want to risk an oil gallery getting clogged

I think this rebuild is taking longer than mine, mmmmmm.
Mine was off the road close to a year, while I redid the bodywork and refreshed the engine.
I'm looking at some 044's as I need to replace the heads, so thought it best to up the spec a bit.

Yeah you're right, I barely touched it all Summer.......

I finally pulled my finger out and took the case to Dr Nomates Engine Emporium this morning.



With the case split his initial prognosis was good. Everything looked as it should.



Out with the crank assembly





However. When we looked at the bearings it seems that the expression I was looking for was 'Bollocks'!

The main bearing journals at the flywheel end of the case were so knackered they seemed to have been shimmed just to be able to get the oversize bearing in.



So, in a nutshell the case is toast, and it leaves me with a decision.
Do I buy a brand new case, (so I know that the journals are pukka), get bearings and reassemble, or do I look around and see if I can buy a built up longblock, but from a reputable engine builder?

Scoops, can you clarify what you mean by this:

"The main bearing journals at the flywheel end of the case were so knackered they seemed to have been shimmed just to be able to get the oversize bearing in."

Not sure what you mean, can show any pics or drawings about the problem you've found?

The case has been line bored.
The first bearing journal has been bored to a larger dia than the others, and required a shim, in addition to the top size bearing it had to have a shim in there to make it fit!
There was also one area that showed wear but the rest was ok, showing that it was probably out of round.

I assume the shimming was done by a machine shop?

Can a machine shop save the case, or is it completely buggered?
Shim it and line bore it again?