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 56astro
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| posted on May 19th, 2005 at 10:33 PM |
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Hows the progress Damien
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa |
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hellbugged
A.k.a.: Daimo Pell
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| posted on May 19th, 2005 at 11:35 PM |
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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 ]
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Turbo54
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| posted on May 20th, 2005 at 03:50 PM |
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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
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.
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hellbugged
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| posted on June 4th, 2005 at 11:24 PM |
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case machining
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 ]
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hellbugged
A.k.a.: Daimo Pell
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| posted on August 30th, 2005 at 10:23 PM |
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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 ]
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pete wood
A.k.a.: figure itout
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| posted on August 31st, 2005 at 11:28 AM |
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So what does the car look like? pics
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hellbugged
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| posted on September 13th, 2005 at 06:42 PM |
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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 ]
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hellbugged
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| posted on September 13th, 2005 at 06:49 PM |
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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 ]
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pete wood
A.k.a.: figure itout
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| posted on September 13th, 2005 at 09:27 PM |
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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?
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hellbugged
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| posted on September 16th, 2005 at 10:31 PM |
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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 ]
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hellbugged
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| posted on September 20th, 2005 at 08:39 PM |
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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 ]
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hellbugged
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| posted on September 20th, 2005 at 09:03 PM |
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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 ]
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hellbugged
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| posted on September 20th, 2005 at 09:17 PM |
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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 ]
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rubyred
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| posted on September 22nd, 2005 at 06:09 PM |
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found out about this thread in your other post, looks like youve got a killer combo there. good luck!
-Ryan
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jakjones
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| posted on September 22nd, 2005 at 08:08 PM |
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Great stuff
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hellbugged
A.k.a.: Daimo Pell
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| posted on October 10th, 2005 at 07:57 PM |
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polished the intake ports, happy with the results, but a lil more refining will be needed.
[ Edited on 27-11-05 by dumone ]
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hellbugged
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| posted on October 10th, 2005 at 08:02 PM |
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then it was onto the exhaust ports.how rough is the casting!!!
not for long..
[ Edited on 27-11-05 by dumone ]
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hellbugged
A.k.a.: Daimo Pell
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| posted on October 25th, 2005 at 07:12 PM |
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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 ]
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hellbugged
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| posted on October 25th, 2005 at 07:22 PM |
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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 ]
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hellbugged
A.k.a.: Daimo Pell
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| posted on October 25th, 2005 at 07:41 PM |
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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 ]
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hellbugged
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| posted on November 15th, 2005 at 08:17 PM |
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manifolds
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 ]
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hellbugged
A.k.a.: Daimo Pell
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| posted on November 15th, 2005 at 08:24 PM |
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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 ]
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56astro
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| posted on November 16th, 2005 at 07:17 AM |
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Nice work Damien.
Should be picking up heaps of performance there
:thumb
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
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Dasdubber
A.k.a.: Alan Agyik
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| posted on November 16th, 2005 at 07:36 AM |
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Great progress pics - it is fantastic to see this sort of detailed rebuild, and all the work involved. It is easy to see how $$ rack up quickly when
you have to pay a shop for all the labour to get these things sorted. Well done. :thumb
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koolkarmakombi
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| posted on November 16th, 2005 at 01:50 PM |
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before you weld them, remove the bushes and see if offsetting one a few mm will get you on track, the holes left in the manifolds may not have been
centred.
kkk
This disclaimer does not reflect the thoughts or opinions of either myself, my company, my friends, or my dog: don't quote me on that; don't
quote me on anything; this disclaimer is subject to change without notice; text is slightly enlarged to show detail; resemblance to actual persons,
living or dead, is unintentional and coincidental; dry clean only; do not bend, fold, or mutilate; anchovies or jalapenos added to this disclaimer
upon request; your mileage may vary; no substitutions are allowed; for a limited time only while supplies last; offer void where prohibited; this
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Louis
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| posted on November 16th, 2005 at 02:00 PM |
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#! Message No Longer Available !#
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hellbugged
A.k.a.: Daimo Pell
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| posted on November 16th, 2005 at 10:14 PM |
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^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
hope so astro
thanx sir das, its gonna drag on but thats what i'm trying to show. real v.w motors cost big $$$
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 ]
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 helbus
A.k.a.: Pete S
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| posted on November 16th, 2005 at 10:18 PM |
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I reckon the level of pride and attention to detail is fantastic. :thumb
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bond
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| posted on November 17th, 2005 at 05:45 PM |
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true that! love it!
nick
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StenGuns
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| posted on November 17th, 2005 at 06:09 PM |
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Good Job.. Is that an un-loved dual cab in the background?
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