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 dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 12th, 2009 at 07:37 AM |
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I should mention that the washing of the barrels is at the final assembly time and AFTER all machine work and honing.
Now the head studs are too long to clear the inlet manifold, easilly shortened..lucky it is at trial assembly stage to find this.
Check deck heights:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 12th, 2009 at 07:40 AM |
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Machine piston tops to correct very minor variances and re-balance.
Check piston to valve with light springs:
(camshaft was "dialed in" a couple of degrees adanced long before this check).
And machine heads to make it all sweet.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 12th, 2009 at 07:42 AM |
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Manifolds:
Match port with this:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 12th, 2009 at 07:55 AM |
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The chambers and ports were hand blended and CCed.
Both valves and seats needed to be machined to optimise piston to valve clearance.
New rings were gap filed.
Barrels and heads were then trial fitted.
Spirolocs are a pain, but the best way to retain the pins in the piston.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on September 12th, 2009 at 07:59 AM |
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Geometry was corrected with 30 thou shims under the rockers and an adjustable pushrod to get the length correct.
This photo shows the pushrod in line with the adjuster at half lift. (.280").
Then make the pushrods the correct length.
These are Manton .058 wall chromoly.
Springs were shimmed and travel of valves set to 1.5mm over valve lift. (only needed one shim of various thickness under each valve spring).
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 12th, 2009 at 08:02 AM |
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At final assembly some areas required machining so the valve covers wuld clear:
Just about done:
Ahhh!
| Quote: | Originally
posted by westi
That's mad Alan.
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Scarab
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| posted on September 12th, 2009 at 10:19 AM |
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Mate....that is some SERIOUSLY AWESOME work there!! love all the step by step photos.....it gives new inductees to VW's (like me) a great insight
into these engines, thanks mate!
I have rebuilt heaps of engines in the past, but never aircooled....the fear of the unknown has been putting me off a little, but your 'in progress'
shots have helped to cure that fear, cheers!
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cnfabo
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| posted on September 12th, 2009 at 10:56 AM |
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what sought of horses would we expect out of this combo dave ?
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humpty
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| posted on September 12th, 2009 at 11:21 AM |
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My God Dave, you never cease to amaze me... Reub's a lucky lad to have wrangled you into this build!!!! His lil'58 is gonna tramp the Purple car for
sure!!! 
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Craig Torrens
A.k.a.: Craig Torrens
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| posted on September 12th, 2009 at 08:44 PM |
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looks like you had to fix up a lot of poor machining previously done to the heads, that's a pity for Reubs considering he paid good money for them !
Not long now Reubs and you will be kicking arse :cool
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bugking
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| posted on September 12th, 2009 at 10:15 PM |
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nice 58 you have there, wish i had the skills to rebuild an engine, or the cash to get it done! Its great to watch how the pros do it.
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hellbugged
A.k.a.: Daimo Pell
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| posted on September 13th, 2009 at 08:41 AM |
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 ..........thanx DB, great read
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 13th, 2009 at 02:57 PM |
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Reubs manifolds getting machined flat.
The first job on the new Milling machine!
| Quote: | Originally
posted by westi
That's mad Alan.
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Craig Torrens
A.k.a.: Craig Torrens
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| posted on September 14th, 2009 at 10:42 PM |
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so are you just running single valve springs for the cam 'run in' or is that how its going to be ?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on September 15th, 2009 at 05:34 AM |
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Hi Craig, just single springs to run the cam in.
Then Rueb will have to re-fit the inner springs.
| Quote: | Originally
posted by westi
That's mad Alan.
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colonel mustard
Son of Jim - Creator of Good
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| posted on September 22nd, 2009 at 09:23 AM |
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What is it with you and couriers!
Cant wait to see then new setup in the 58 
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colonel mustard
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| posted on October 18th, 2009 at 02:13 PM |
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Woot Woot!
Video!! Pictures!!
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hellbugged
A.k.a.: Daimo Pell
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| posted on October 18th, 2009 at 02:48 PM |
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are you good for the tool to remove valve springs in situ after run in Reubs???
happy to send mine up if you like.
let me know
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colonel mustard
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| posted on October 18th, 2009 at 02:54 PM |
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| Quote: | Originally
posted by reub-revhead
No vids or pics yet - we've all seen a volksie engine and heard one running?? 
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have to push mine... can't afford the fuel.
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humpty
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| posted on October 18th, 2009 at 06:56 PM |
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| Quote: | Originally
posted by reub-revhead
The engine lives!! After ensuring there was oil pressure I connected up the fuel pump and hey presto, it started on the first try (just like on TV!).
I look forward to driving the car...
HUGE THANKS TO DAVE!
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Great news mate.... How's she feel?
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colonel mustard
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| posted on October 18th, 2009 at 09:22 PM |
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I knew you would give in to vw peer presssue. hhahaha.
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trickysimon
A.k.a.: Simon Azzopardi
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| posted on October 18th, 2009 at 09:34 PM |
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Sidewinder sounds good aye 
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colonel mustard
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| posted on October 18th, 2009 at 09:45 PM |
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Here is my first youtube vid... http://www.youtube.com/watch?v=rgnSJHqAy24&feature=channel
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humpty
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| posted on October 19th, 2009 at 12:42 AM |
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Smooth as Reuben... Smooth as.
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Camo
A.k.a.: Kev
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| posted on October 19th, 2009 at 10:20 AM |
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| Quote: | Originally
posted by Scarab
Mate....that is some SERIOUSLY AWESOME work there!! love all the step by step photos.....it gives new inductees to VW's (like me) a great insight
into these engines, thanks mate!
I have rebuilt heaps of engines in the past, but never aircooled....the fear of the unknown has been putting me off a little, but your 'in progress'
shots have helped to cure that fear, cheers!
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Have to agree with the above and pass on my thanks to Dave for all the great photos, they are a great help and to Reub for spending the money so
others can learn
Cheers, Kev
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on October 20th, 2009 at 05:18 AM |
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Taken it for a drive yet Reub!?
| Quote: | Originally
posted by westi
That's mad Alan.
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colonel mustard
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| posted on December 12th, 2009 at 11:38 PM |
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 matberry
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| posted on January 9th, 2010 at 08:00 PM |
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Great progress mate. Good to see the Haltech system using all those yummy black fittings, should look really nice . Keen to hear how the cooling system performs up your way, that'll test it
out for sure.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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matberry
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| posted on January 9th, 2010 at 08:21 PM |
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Over 7500-8000 rpm I believe. Never used them myself, although my old 2165 did turn 9000 it also had oil issues and no drains.....
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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colonel mustard
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| posted on January 9th, 2010 at 09:09 PM |
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I'm not a huge fan of the cooling system there (haha, get the pun...), but only because it looks abstract - But, things are designed the way they are
for a reason, so i wish you the best of luck with it.
Intake and ignition look HOT!!!! a fine setup you have going there mate. 1 month goal sounds good!
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