OK. I have "AD" 1600 engine I am rebuilding the top end of for a ex army gen set. I have got it stripped back to the block. I have found the cylinders have a small lip in them and piston number 3 looks to have gotten hot at some stage. The exaust valve on no. 3 is also burnt. The plan was to get the heads sorted, hone the cylinders and fit a fresh set of rings. How does this sound?. The engine will be lucky to do 10hrs a year. What is the story with over size rings. Can I use my current pistons and cylinders and use over size rings. Or should I go with standard.
Thanks Brett

Dude
IMHO, If its a stationary engine, just fix the valve, give it a de-coke, hand hone it with 280 wet & dry and whack a stock set of rings back in her and fire away.

Dun waste ur time and hard earned readies bothering to "polish a turd"

L8tr
E

I would just use the standard rings...
You have to get the cylinders machined and New pistons to go larger....
You can pick up a good 1600 cylinder easily enough at most wreckers etc... Just hone it...

Its unusual for a Power Generator to over heat IMHO...

but I'm pretty sure that Your engine would be a single port 1600 with the early style oil cooler which sits over NO 3 cylinder, which gets preheated air after it goes thru the oil cooler.... this system was introduced in 1938...
and Many VW engines have dropped valves etc with No 3 cylinder... over the years....

they changed this system in 1971 when the doghouse oil cooler was introduced along with a wider fan etc...
the air then goes thru the new oil cooler and the hot air is then sent out of the front of the Fan shroud near the gearbox...

I would just use 2nd hand parts to repair the engine...
although New rings wouldn't be expensive....

Best of Luck.... I did see one of these units a few months ago.. a few of the locals have them...

Lee

http://community.webshots.com/user/vw68autobug 

Sorry for the mislaeding info, the motor is a 1600 twin port ex super bug that I had in the shed. I have stripped it down to check what it needs to become my stationary motor. I have got a set of single port heads to go on. Its seems a quck polish, lap the valves, new rings and its away. Do I need to replace the burnt piston. I will try and post pictures tomorrow night.
Thanks for the help.
Brett

if it has a hole in it... er, yes!