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 Project Back to '91!

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vietnam
DBS Old Timer
DBS Old Timer
vietnam

Male Number of posts : 1671
Age : 30
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyMon Nov 12, 2012 12:14 am

Nice to see some reengineering rather than just replacing it all Smile
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clockwork
DBS Top Sphincter
DBS Top Sphincter
clockwork

Male Number of posts : 7198
Age : 48
Location : Wouldn't I like to know
My Ride(s) : Rollercoaster
Registration date : 2009-08-09

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyMon Nov 12, 2012 5:25 am

Good work Al..coming along nicely Very Happy
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Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySat Mar 16, 2013 10:27 pm

Bit more done..

Combustion chamber reshaped and cc'd

Project Back to '91! - Page 5 92EEFE3A-DD1C-40EA-9A5E-DB2F9997AE35-2465-000005F3781087D3

Spark plug hole drilled

Project Back to '91! - Page 5 08DCC393-E296-4FAC-8C85-9F958785DEF6-2465-000005F36962281B

Valves all fitted

Project Back to '91! - Page 5 C7A206C2-B8E3-459C-9BDF-B6D38A2A3E11-2465-000005F359787B09

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
a.k.a. Clunge, The Club Deviant
Gungemyster

Male Number of posts : 12659
Age : 48
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySat 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
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun 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
DBS Old Timer
DBS Old Timer
vietnam

Male Number of posts : 1671
Age : 30
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun 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
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun 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
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyMon 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!

Project Back to '91! - Page 5 Null-2

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

Left a bit of an indentation though

Project Back to '91! - Page 5 Null-4

Bit of rubbing down

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Light smothering with filler

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Rubbed down

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Primed

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Top coat is done, but I'll take more pics later when I flat and polish.
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Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed May 15, 2013 7:24 pm

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

Project Back to '91! - Page 5 Null-10

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!

Project Back to '91! - Page 5 Null-11

Time to start getting the engine together now!
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Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu May 16, 2013 8:07 pm

Woo Hoo! I now have a complete longblock!

Project Back to '91! - Page 5 Null-12


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
DBS Top Tater
DBS Top Tater
Mr Scoops

Male Number of posts : 38009
Age : 46
Location : Weston super Dooper
My Ride(s) : 1991 Vanagon GL Westfalia 2.1: 2011 A3 S-Line
Registration date : 2006-08-19

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu May 16, 2013 9:02 pm

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

_________________
Project Back to '91! - Page 5 Pbucket
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http://www.cttp.co.uk
vietnam
DBS Old Timer
DBS Old Timer
vietnam

Male Number of posts : 1671
Age : 30
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu May 16, 2013 9:33 pm

Sweet! It's been a long time coming Wink
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Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun 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.

Project Back to '91! - Page 5 Null-14

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

Project Back to '91! - Page 5 Null-13

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
DBS Old Timer
DBS Old Timer
tango_van

Male Number of posts : 2846
Age : 38
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun May 19, 2013 8:03 pm

Looking good Al!
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dubberatlast
DBS Top Tater
DBS Top Tater
dubberatlast

Male Number of posts : 15756
Age : 41
Registration date : 2006-09-01

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun May 19, 2013 9:33 pm

good work mate.
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Gungemyster
a.k.a. Clunge, The Club Deviant
a.k.a. Clunge, The Club Deviant
Gungemyster

Male Number of posts : 12659
Age : 48
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptySun May 19, 2013 10:51 pm

Well done mate
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Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed 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.

Project Back to '91! - Page 5 Null-15

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

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10 minutes later!!

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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
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed May 29, 2013 6:30 pm

nice one dude ......good job
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Mr Scoops
DBS Top Tater
DBS Top Tater
Mr Scoops

Male Number of posts : 38009
Age : 46
Location : Weston super Dooper
My Ride(s) : 1991 Vanagon GL Westfalia 2.1: 2011 A3 S-Line
Registration date : 2006-08-19

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed May 29, 2013 9:07 pm

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

_________________
Project Back to '91! - Page 5 Pbucket
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http://www.cttp.co.uk
Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed 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
DBS Top Tater
DBS Top Tater
Mr Scoops

Male Number of posts : 38009
Age : 46
Location : Weston super Dooper
My Ride(s) : 1991 Vanagon GL Westfalia 2.1: 2011 A3 S-Line
Registration date : 2006-08-19

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyWed May 29, 2013 9:33 pm

Bummer

_________________
Project Back to '91! - Page 5 Pbucket
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http://www.cttp.co.uk
Big_Al
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu May 30, 2013 1:06 pm

Bracket fabbed,

From this

Project Back to '91! - Page 5 Null-18

To this

Project Back to '91! - Page 5 Null-19

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
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu 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
DBS Old Timer
DBS Old Timer
Big_Al

Male Number of posts : 3614
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu 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
DBS Top Tater
DBS Top Tater
nomates

Male Number of posts : 18609
Age : 47
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

Project Back to '91! - Page 5 Empty
PostSubject: Re: Project Back to '91!   Project Back to '91! - Page 5 EmptyThu May 30, 2013 6:24 pm

cool
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