Craig also made up some sacers for below the springs.
These are a special($) conical spring now available that can be fitted with a locator at the spring base.
Craig modified the original retainer to use these.
I was able to use normal spring shims underneath the lower locator, to equalize the travels and tensions.
For this application, and cam shaft, the copression was chosen to be around 9:1.
This meant tht the heads needed to be fly cut.
the first CC came out at 65, with no hand work.
I also found this problem that seems common to all the CNC heads that have come from CB.(that I have worked on).
The exposed threads are just pre-ignition waiting to occur.
On some cylinder heads, the large outside diameter of the shims can prevent the seal from seating properly.
This modification was done on a mandrel on the lathe:
Next it was found that the larger tube would interfere with the "cool tin".
It would have weakened the tin to the point of failure had I clearanced it,
...so some good old fashioned early tin was trial fitted, and then cleaned/painted to do the job.
The final step was to set up the rocker clearance and geometry,
and make the pushrods.
For this engine we are using the manton dual tapered chrome-moly versions.
Andrew may try some of the special aicooled.net dual tapered aluminium ones in the future,
since this engine only having fairly low spring tension,
a (weaker) alum p'rod could be less noisy when hot.
The simple rule of thumb was to have a pushrod and rocker post shim and lash cap combination,
that allows for the adjuster to be inline with the push rod at half lift.
In this case the lift point of .264" was chosen,
and then the assembly cycled to observe the roller tip only swept a small amount across the valve tip.
Thinking I was only minutes from completion,
by bolting on the rocker covers,
I realized that the hardware included would not match the larger 3/8" UNF studs, used to clamp down the Pauter rockers.
Once I drilled out the covers, and made some studs,
the seals would no longer fit:
how do you say thanks for a build like this???????
Firstly i need to thank the guys at CE. Craig and Mark have been advising, teaching and helping me through this VERY long engine build.
Pat Downs at CB also was a good source of advice and it was appreciated.
And finally Dave for the assembly. fantastic pics and it really shows the care and attention that you pay to your work. i also need to thank you for the gear box that is currently in the car waiting for perfect pairing 2276 and a stong box.
Over the next few weeks i will be finishing the tinware and the EFI. then it is off to the dyno for run in and tuning.
After four years of purchasing, preparing, postponing, moving from Sydney to NZ and back to Brisbane (the car has travelled with us) it is SOOOOOOOOOOO close now.
My wife would't let me have the engine in the lounge so at the moment it is in the wardrobe. but i look at it every night.
Ever since I got into VWs two years ago I have been told: There are engine builders, and then there are engine builders.
I think the work done on this one demonstrates the enormous amount of time, skill and knowledge required to build an engine well.
Unfortunately it also highlights to me how lacking I am in at least two of the three attributes that I listed when it comes to rebuilding my own engine 😢
Well done Dave and I'd like to see and hear this engine in person one day.
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
thanks hellbugged. it has been a while since i have driven a quick bug. it is a big step up from the 1916 i used to run.
can wait to get back in the seat.
Craig Torrens6 times Australian, 7 times State Hillclimb Class Champion
when i bought the car, it already had bracing from the forks to the body, so i will see how that goes.
as far as Tyre, I can't remember what brand/model they are but they were recommended by a circuit racer, so hopefully they should be fine.
had a chance to get some work done on the accessaries. the tinware was a pain in the neck though but it looks like it's all together now.
just working through the manifolds and throttle bodies. hopefully next weekend i can start to get the engine into the car.
