56astro Custom Title Time!
1,772 posts · joined Aug 2002 ·
Hows the progress Damien
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
The last Hellbug
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
progress is happening steve. got the cutters sorted for the guide boss and guide end to be cut down for dual springs, needed to make a plate to hold the heads at the correct angle on the drill press table, so thats been the job for the week. the plate will come in handy when the springs get shimmed later, so its all part if the process. damo:thumb
pic shows where i skimmed to check cutters, guide needs to be shaved for retainer clearence and also to allow cutter to reach down to spring seat when the boss is cut for inner springs
[ Edited on 25-10-05 by dumone ]
pic shows where i skimmed to check cutters, guide needs to be shaved for retainer clearence and also to allow cutter to reach down to spring seat when the boss is cut for inner springs
[ Edited on 25-10-05 by dumone ]
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Turbo54 Veteran Volks Folk
2,220 posts · joined Jul 2004 ·
Wouldn't run the air filter in the bay where it could suck hot air. Better off doing you own thing. If you need any ideas I will give you an address to go to for all your turbo questions. There's a few know it all's on the site but you get them everywhere...
T54
T54
C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
slow start over the last couple of weeks, managed to get the case machined for the washer and nut conversion. the washer lands have now been spot faced to accept the larger diameter washer and 15mm wrench size nuts. not a hard job, just fiddly, the holes were first drilled to 10mm, then each face machined till the nut was getting a full thread, depths vary, and a couple of spots require the stud to be backed out ever so slightly.case can now be torqued to 30pds, prevents shuffling of case 1/2s and consequently extends the life of it.
[ Edited on 27-11-05 by dumone ]
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
well a few weeks of delays have come to an end, and its time to get going!not that i'm complaining 'bout the delays- front and rear whiteline sway bars,new pads on the front with late style spindle nuts,6 point roll cage installed, and good progress on ea rear discs,shift light and the "winter break" just up the road, but the biggy was breaking the spot face tool with only a couple of holes remaining.several drill bits were tried and failed before going to cobolt with success.heres a pic of the tool used for spotfacing.its a head stud with tapered end, cross drilled with a cut down drill bit as the cutter- simple but effective.engineers suppliers couldn't provide a cutter with enough shank length to go past the sump.
[ Edited on 27-11-05 by dumone ]
[ Edited on 27-11-05 by dumone ]
pete wood 23 Windows of Awesome
6,828 posts · joined Jan 2004 ·
So what does the car look like? pics
"stoopid is stronger than axles"
http://drivingnotpolishing.blogspot.com.au/
http://drivingnotpolishing.blogspot.com.au/
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
a lovely day under the sun to practice porting and polishing. had a play on some old heads, as my new ones have had bigger seats installed, but now there is a dirty big step left where the smaller seats were. so with the aid of some tried and true port templates, and shirtloads of reading, looking and talking,they're gonna get ported...
like the foot step for getting up above the bench??
[ Edited on 27-11-05 by dumone ]
like the foot step for getting up above the bench??
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
whilst the die grinder was out, cut the flange on the rear of the case to clearence the anti-shocker...
[ Edited on 14-2-06 by dumone ]
[ Edited on 14-2-06 by dumone ]
pete wood 23 Windows of Awesome
6,828 posts · joined Jan 2004 ·
I was reading about those anti-shockers today on the Berg site, so that's what they look like. Have you used it yet, or is it a brand newie?
"stoopid is stronger than axles"
http://drivingnotpolishing.blogspot.com.au/
http://drivingnotpolishing.blogspot.com.au/
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
yeah Pete, its a newie.the couple of people i have spoken to that have used them, swear by them.my old 2180 came to an end after a fouled clutch engagement,so when i came accross it sitting in a box, i struck a deal with the owner, paid him, and then let him know they are no longer available.
[ Edited on 14-2-06 by dumone ]
[ Edited on 14-2-06 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
finished off head holder for porting and table for holding heads on drill press table, at correct angle to cut guide bosses. think they're stong enough! then, forced myself to dive into my n.o.s dual port heads.
[ Edited on 27-11-05 by dumone ]
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
the templates used during practice were deemed too large for my castings, so a compromise template was knocked up.discovered the hole in the center of the gasket was useful for alignment when flipping the template from one port to the other.now, the theory goes that the template would provide the guidlines for how far to go on that end,........
and the step behind the valve seats would be the starting point for the other. then its a matter of linking the two up.....
... my method to keep the ports as even as possible was to do as much as possible with the reach of a particular cutter- on each port(intake), before switching to the next cutter with a longer reach,cleaning up and removing bumps/ highs as i went.not much material has been taken down in the ports, maybe 1 or 2mm, some reshapping was required in the roof area and and the turn above the guides. guides,casting around guides, and bump from spring seat inside inlet ports, will all not be removed-only streamlined/polished to keep air speed and therfore tourque.....
[ Edited on 27-11-05 by dumone ]
and the step behind the valve seats would be the starting point for the other. then its a matter of linking the two up.....
... my method to keep the ports as even as possible was to do as much as possible with the reach of a particular cutter- on each port(intake), before switching to the next cutter with a longer reach,cleaning up and removing bumps/ highs as i went.not much material has been taken down in the ports, maybe 1 or 2mm, some reshapping was required in the roof area and and the turn above the guides. guides,casting around guides, and bump from spring seat inside inlet ports, will all not be removed-only streamlined/polished to keep air speed and therfore tourque.....
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
taking it slowly was the go! 6hours saw four ports done from the manifold side down to the back of the guide (not polished)
and two done from behind the seats down...
[ Edited on 27-11-05 by dumone ]
and two done from behind the seats down...
[ Edited on 27-11-05 by dumone ]
rubyred Slammed & Awesome Dubber
77 posts · joined Apr 2005 ·
found out about this thread in your other post, looks like youve got a killer combo there. good luck!
-Ryan
-Ryan
jakjones Officially Full-On Dubber
217 posts · joined Mar 2004 ·
Great stuff
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
polished the intake ports, happy with the results, but a lil more refining will be needed.
[ Edited on 27-11-05 by dumone ]
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
then it was onto the exhaust ports.how rough is the casting!!!
not for long..
[ Edited on 27-11-05 by dumone ]
not for long..
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
hooray!!!!24 hours labour all ports are ported and polished.these pics didn't come up real well, but the batteries went flat, so i will try to replace these photos with better ones later.
first piccy shows the tools needed, for those who might be interested (i had no idea what they looked like a month or so ago)-assortment of carbide burs-emery rolls and shaft-flapper wheels which are like lil strips of emery cloth-and the way cool kitchen scourer scuffer which did the final pass and produced a mirrorish finish- the bolt and sleeve i made up to protect the valve guides-proven template and water cooled kombi exhaust gasket(sitting atop standard beetle) was used for the exhaust size.
few more shots of the places of interest.
[ Edited on 23-6-07 by dumone ]
first piccy shows the tools needed, for those who might be interested (i had no idea what they looked like a month or so ago)-assortment of carbide burs-emery rolls and shaft-flapper wheels which are like lil strips of emery cloth-and the way cool kitchen scourer scuffer which did the final pass and produced a mirrorish finish- the bolt and sleeve i made up to protect the valve guides-proven template and water cooled kombi exhaust gasket(sitting atop standard beetle) was used for the exhaust size.
few more shots of the places of interest.
[ Edited on 23-6-07 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
the steps left under the new larger seats are now long gone!
as you can see the guide boss was just streamlined and blended around the top edge, and the sides of it polished.
no trick photography or backlights, they really are that smooth.these shots were not even taken in direct sunlight
[ Edited on 27-11-05 by dumone ]
as you can see the guide boss was just streamlined and blended around the top edge, and the sides of it polished.
no trick photography or backlights, they really are that smooth.these shots were not even taken in direct sunlight
[ Edited on 27-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
phat exhaust ports! went right out to the scribe line from the kombi gasket. found out a bit too late that leaving it 1.5mm off the line would have given more low end tourque rather than high rpm flow, but the guide bosses remaining will balance it back a bit.nice oval shape of the short side will help.
i'm stoked, thanx for lookin.
wonder how many hours the combustion chambers and matching the manifolds will take???..... they're next.
[ Edited on 26-11-05 by dumone ]
i'm stoked, thanx for lookin.
wonder how many hours the combustion chambers and matching the manifolds will take???..... they're next.
[ Edited on 26-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
well from little things, big things grow
lets match port the manifolds! o.k so the first thing you do is sit them on the heads, only to discover they are loose as buggery on the studs due to years of installing and removal- the holes in the soft aluminum have become oversize.
A fix was soon sorted with some stainless steel bar being turned down and cored to within one poofteenth of nada(not much).put it this way, the studs were 8mm and the holes in the manifolds 9.2mm that makes for a very small bushe.
now thats sorted and they are tight on the heads with no movement-slop-which will allow a good match port to realign each time the manifolds are removed and reinstalled in the future.
next problem
even with the rather large port job i've gone to, the hole in said manifolds aren't quite machined right and open up beyond the edge of the holes in the heads- thats bad and interesting how its on the same point on both-they will have to be tig welded where the blue marker shows, before i can do any more.
[ Edited on 26-11-05 by dumone ]
lets match port the manifolds! o.k so the first thing you do is sit them on the heads, only to discover they are loose as buggery on the studs due to years of installing and removal- the holes in the soft aluminum have become oversize.
A fix was soon sorted with some stainless steel bar being turned down and cored to within one poofteenth of nada(not much).put it this way, the studs were 8mm and the holes in the manifolds 9.2mm that makes for a very small bushe.
now thats sorted and they are tight on the heads with no movement-slop-which will allow a good match port to realign each time the manifolds are removed and reinstalled in the future.
next problem
even with the rather large port job i've gone to, the hole in said manifolds aren't quite machined right and open up beyond the edge of the holes in the heads- thats bad and interesting how its on the same point on both-they will have to be tig welded where the blue marker shows, before i can do any more.
[ Edited on 26-11-05 by dumone ]
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
thats a small bush, but surprising how much the mannies moved without em. i never thought i would become this maticulous, having no time goals helps.
there is something sexy about a clean pair of heads with some beefy manifolds sitting atop.we're getting closer SLOWLY.
[ Edited on 14-2-06 by dumone ]
there is something sexy about a clean pair of heads with some beefy manifolds sitting atop.we're getting closer SLOWLY.
[ Edited on 14-2-06 by dumone ]
56astro Custom Title Time!
1,772 posts · joined Aug 2002 ·
Nice work Damien.
Should be picking up heaps of performance there
:thumb
Should be picking up heaps of performance there
:thumb
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
Dasdubber DAS Resto Haus
5,746 posts · joined Aug 2002 ·
Great progress pics - it is fantastic to see this sort of detailed rebuild, and all the work involved. It is easy to see how $$ rack up quickly when you have to pay a shop for all the labour to get these things sorted. Well done. :thumb
koolkarmakombi enkarmarising
2,078 posts · joined Jun 2003 ·
before you weld them, remove the bushes and see if offsetting one a few mm will get you on track, the holes left in the manifolds may not have been centred.
kkk
kkk
This disclaimer does not reflect the thoughts or opinions of either myself, my company, my friends, or my dog: don't quote me on that; don't quote me on anything; this disclaimer is subject to change without notice; text is slightly enlarged to show detail; resemblance to actual persons, living or dead, is unintentional and coincidental; dry clean only; do not bend, fold, or mutilate; anchovies or jalapenos added to this disclaimer upon request; your mileage may vary; no substitutions are allowed; for a limited time only while supplies last; offer void where prohibited; this disclaimer is provided "as is" without any warranties expressed or implied
Louis Commited Dubber
50 posts · joined Nov 2005 ·
It is hard to tell from the photos but the inlets should not be too highly polished. Exhaust ports are great to be very finely polished but the inlet being too smooth will encourage the fuel to liquid rather than keep it atomised.
hellbugged 48's and straight cuts
5,080 posts · joined Apr 2003 ·
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
hope so astro
thanx sir das, its gonna drag on but thats what i'm trying to show. real v.w motors cost big $$$
nice idea koolkarma, looked at it, but both holes would need rebushing and they seemed to sit parralel to the tappet cover gasket surface idicating a machining fault? damn chinese child slave labour.
hi louis, very true, the end polish is more about pride of workmanship than gaining fractions of H.P yes. some turbulence is good (atomisation). turbulence over lips on things like mismatched manifolds, gaskets and exhausts is bad.realising you would already know that
[ Edited on 20-11-05 by dumone ]
hope so astro
thanx sir das, its gonna drag on but thats what i'm trying to show. real v.w motors cost big $$$
nice idea koolkarma, looked at it, but both holes would need rebushing and they seemed to sit parralel to the tappet cover gasket surface idicating a machining fault? damn chinese child slave labour.
hi louis, very true, the end polish is more about pride of workmanship than gaining fractions of H.P yes. some turbulence is good (atomisation). turbulence over lips on things like mismatched manifolds, gaskets and exhausts is bad.realising you would already know that
[ Edited on 20-11-05 by dumone ]
helbus Administrator Mad fabricator, paint and body
7,386 posts · joined Sep 2002 ·
I reckon the level of pride and attention to detail is fantastic. :thumb
bond Veteran Volks Folk
2,456 posts · joined Jul 2003 ·
true that! love it!
nick
nick
StenGuns Veteran Volks Folk
2,147 posts · joined Mar 2004 ·
Good Job.. Is that an un-loved dual cab in the background?