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 bond
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| posted on June 26th, 2007 at 09:03 PM |
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there is only 1 - don damo 
looking forward to pics alan!
whats the plans exactly for warwick then - n/a? then sort the turbo stuff for the street/strip afterwards???
nick
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Dasdubber
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| posted on June 26th, 2007 at 10:17 PM |
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Craig - yep, Damo has access to some pretty cool cleaning facilities at his work (aircraft engine mechanic/engineer (sorry damo not sure of your exact
title)). I could eat off it but didn't want to get it dirty!
Nick in regards to warwick - I am confident I can get the box ready (thanks to dangerous), and long block built (if RAT gets my order processed sooner
than later). I don't think I will have the time or money to sort out the EFI/turbo stuff by then, so I may borrow a pair of carbs and just run it N/A
to have some fun. Won't be fast, but at least I will be able to race which is all part of it....I only ran a best of 10.5sec in the 1/8 last year but
I had so much fun, I couldn't wait to get back out there!
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Dasdubber
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| posted on July 3rd, 2007 at 09:33 PM |
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Well, finally the head disassembly tool arrived so I stripped the heads (although valve guides and seats will remain in place as they were done when
the engine was rebuilt for the ragtop).
Here they are before any work began - valves are 1800 size (41mm inlet and 33 exhaust) with 2L chambers:
When the heads were rebuilt, I feel there was too much material removed from under the exhaust valve seat on the short radius...so I will probably
expect a dropped seat or two eventually (hopefully not for a little while).
Ports will just receive a bit of clean up and smooth out.
Inlets pre-porting
Exhausts pre-porting
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Dasdubber
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| posted on July 3rd, 2007 at 09:39 PM |
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I should now put a disclaimer up and say I am by no means an expert (far far from it) - I have tried to read and research as much as I could about
porting techniques and theories and have asked questions of guys with more experience than me (not hard!). I am not striving for perfection with this
engine, remember it is a chance for me to actively learn about assembly techniques and familiarise myself with turbo/efi applications etc, as well as
porting.
Exhaust port was hard with its sharp bend especially with the guide in place.
I tried to avoid the short radius and spent a bit of time smoothing out the long radius, removing as many imperfections as possible.
I tried to blend the ports into the seats - the deeper pits visible on the right were hard to remove and I wanted to avoid taking too much material
away, so they will stay for now.
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Dasdubber
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| posted on July 3rd, 2007 at 09:44 PM |
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Unfortunately mine won't be quite as clean or tidy as Daimo's (dumone)....but he did give me some inspiration to have a go (along with dangerous's
encouragement). If anyone can see where I have f'ked up or areas I should improve, feel free to let me know as I am here to learn!
The inlet from chamber side:
I opened up the upper inner edge slightly half way down the port as it was visible restriction point - no major mods, again just a slight change and
then a clean up:
The nicks on the guids are from the sanding flap wheel only (not tungten carbide cutter), so hopefully it won't cause any major problems. (fingers
crossed)
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Dasdubber
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| posted on July 3rd, 2007 at 09:47 PM |
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Obviously inlet manifold stud needs repair (stripped out on disassembly).
I do not know enough about chamber design to fiddle with these so they will retain their stock 2L shape - just cleaned the sharp edges in attempt to
avoid hot spots.
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Dasdubber
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| posted on July 3rd, 2007 at 10:00 PM |
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View down the inlet manifolds showed a lip on the lower edge which potentially obstructs flow.....this time around I spent more time ensuring accurate
manifold positioning (would be best to bush the manifolds with say steel inserts to avoid movement and misalignment when bolting them up). I do
however now know what position they need to be in when I install them.
Once I was satisfied with the manifold position, I scribed its position on the head mating surface (at least where the scribe could reach):
Fortunately the manifold ports were perfectly round which made this job easier for me - they were 36mm so I could use my old graphics template to
transfer the manifold port onto the head:
Using the scribed line in the earlier pic as a positioning guide, the template was used to extend the manifold port shape onto the head - of course
this wouldn't work with a non-round manifold port.
Black pen and newly scribed line shows material to be removed and blended into the inlet ports, plus some more smoothing inside the inlet
manifolds.
Remember this is DIY home garage stuff so of course these are not going to flow anywhere near as well as a professionally done job = I am happy to
make that sacrifice to further my knowlege base...even if it is to justify the expense of a professional job down the track (since I now know how
tricky it is to get right!).
More work and hopefully pics on the weekend probably.
Alan
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Dasdubber
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| posted on July 3rd, 2007 at 10:06 PM |
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Forgot to say - rules of thumb which I have read include port size should equal ex valve size...and another 'rule' is port size should be 90% of
inlet valve (which would equal 36.9mm). Original inlet port size was 33mm before mods, I will take it out to 36mm as indicated above and see how it
goes. The turbo should give me some margin of error unlike a naturally aspirated version which this would probably be much more critical.
New Lucas indicators arrived from the UK - still undecided if I will use them but have lots of time to decide as I'll do all the mechanical work
before I tackle paint:
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dangerous
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| posted on July 3rd, 2007 at 10:13 PM |
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Good work Alan!
| Quote: | Originally
posted by westi
That's mad Alan.
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hellbugged
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| posted on July 3rd, 2007 at 10:18 PM |
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 ........nice work
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humpty
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| posted on July 3rd, 2007 at 11:33 PM |
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Top stuff Alan... Tell me mate.... What sort of valves are you planning to run?
And its good to see you can still get those Lucas seals.... I've got an OG amber set that need them!
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Dasdubber
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| posted on July 5th, 2007 at 11:02 PM |
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Well, finally received all the bits required for the gearbox bits.
First up is the Moore midmount (cheers Damo), Super diff, and heavy duty side plate (thanks Rod P)...
A fair chunk of credit card debt later yielded the Albins gears (3.333 1st, 2.08 2nd, 1.40 3rd (would have been an 8 week wait for the 1.44), and 1.04
4th).
Sway-A-Way race axles (not pictured) have also been sourced so hopefully when Dave (dangerous) gets a chance, the gearbox will slowly come together!
In the mean time my dog Sasa guards all my gearbox goodies
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humpty
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| posted on July 5th, 2007 at 11:24 PM |
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Ooooo.... Scary dog...... Nice bits Alan.... Totally jealous...
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koolkarmakombi
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| posted on July 6th, 2007 at 07:42 AM |
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Awesome Alan, I hope the puppy doesnt eat any of those bits!
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
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Dasdubber
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| posted on July 6th, 2007 at 09:16 AM |
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Yeah that course tooth 4th gear wouldn't tickle on the way out!
I wanted to get some pics of the nice shiny gears before they get hidden away inside the tranny
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humpty
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| posted on July 6th, 2007 at 09:44 AM |
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Bugger fitting them to your transaxle..... They'd be pretty flash paper weights!!! 
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bond
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| posted on July 6th, 2007 at 01:04 PM |
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ooo very nice and clean and shiny!!! getting there! well done
nick
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063bug
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| posted on July 9th, 2007 at 05:06 PM |
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Holy smokes..... so much for taking it easy on this one  knew you
couldn't only half do a job..... :thumb |
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Dasdubber
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| posted on July 10th, 2007 at 08:39 AM |
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Yeah you know me Alan
I will stick to my guns (for now) and not paint it until I get all the mechanicals sorted out....so hopefully for warwick the new box will be in as
well as the fresh long block which will just run with carbs and dizzy. After warwick I will start on the turbo integration and EFI upgrade (when funds
allow). After all that is said and done, then I may make it all look pretty (but we'll wait and see as plans seem to have a habit of changing!).
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humpty
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| posted on July 10th, 2007 at 12:45 PM |
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| Quote: | Originally
posted by Dasdubber
...... (but we'll wait and see as plans seem to have a habit of changing!).
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No shit!
:kiss
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Dasdubber
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| posted on July 16th, 2007 at 09:51 PM |
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??
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66deluxe
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| posted on July 16th, 2007 at 10:52 PM |
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Nice photo Alan, now does that feel weird having it back even though only for a little while? Damo.
This is my Volkswagen, there are many like it, but this one is mine. Without me my Volkswagen is useless, without my Volkswagen, I am useless.
61 Karmann Ghia 2110cc type1 w Los Panchito's
66 Deluxe Beetle 2270 type 4
10 Subaru WRX Impreza
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humpty
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| posted on July 16th, 2007 at 11:12 PM |
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| Quote: | Originally
posted by Dasdubber
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Kissin' cousin's....
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063bug
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| posted on July 17th, 2007 at 01:33 PM |
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He must've been excited, look how much he was shaking when he took the photo  |
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Dasdubber
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| posted on August 5th, 2007 at 08:03 PM |
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Well, after a continuing super diff fiasco, the gearbox is finally built thanks to Dave (dangerous) Butler.
Components include (as mentioned previously):
- IRS case converted to swing axle (thanks to Damo for the case)
- 3.88 r&p
- super diff (3rd one and still a dud - thanks to dave for the machining work to get it right)
- 10/15 tooth spider gears
- Albins main shaft plus 3.333 1st, 2.02 2nd, 1.40 4th, 1.04 4th (remembering this is designed for a turbo engine)
- heavy duty side plate
- steel shift forks
- Sway a way axles
I think that is about it. Thanks again to Dave for his persistence with the super diff issue as well as the advice along the way. I can't wait to rip
the 36hp donk (well 20.1 at the wheels) and non syncro tranny out and get ready to have this bad boy copping some abuse!
Alan
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bond
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| posted on August 5th, 2007 at 08:09 PM |
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good to see its coming along alan! is the case getting painted as yet? or down the track?
nick
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Dasdubber
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| posted on August 5th, 2007 at 10:15 PM |
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Probably not at this stage Nick - maybe down the track but for now I just have to get things ready for warwick sooner than later without getting
pretty
Not that there is anything wrong with that! Just no time in this instance
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66deluxe
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| posted on August 7th, 2007 at 06:34 PM |
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Good to see my old case in use again, looks good Alan. Thats going to love getting abused with the type 4 turbo, yip yah.
Damo.
This is my Volkswagen, there are many like it, but this one is mine. Without me my Volkswagen is useless, without my Volkswagen, I am useless.
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Dasdubber
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| posted on August 29th, 2007 at 10:37 PM |
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Thanks again Damo for the tranny case - can't wait to get it into the oval!
Well after a bit of problem with my camera software (now sorted), time to update a bit of progress.
For anyone not frequenting the drag section, during assembly I had some problems with cam to case clearance - after some investigation (during
assembly) the cam bolts that came with the new cam and gear were ~2mm too long and thus hitting the case. Easily fixed by grinding them flush with the
gear.....however whilst trying to figure the problem out, I had the crank in, crank out, cam in, cam out, crank in etc - and on the last time I
dropped the crank in, I misaligned the rear main bearing on the dowel (I checked my scribe line on one side but not the other!)....thus when other
case half was dropped in place and pre-torqued to 12ft/lbs (prior to full torque of 25), and of course crank no longer spun.
Sooooo, new set of bearings was tracked down, sealant all cleaned off....and lesson well learnt!
So with new bearings in place, I was sure to make more than enough alignment marks:
Rear main (no damage this time round!):
One of the scribe lines for cross check of correct seating:
Lowly old stock 71mm crank, stock rods etc (all balanced) - no fancy stuff in here so it will be interesting to see how the stock rod bolts hold up
when boost is applied later this year!
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Dasdubber
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| posted on August 29th, 2007 at 10:45 PM |
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Thanks yet again to Damo for drilling and tapping the case for full flow. Shadek 30mm pump with new full flow cover in place and stock filter location
blocked off:
New front seal in place and DTM support bolted in place:
Curil T used under case bolts etc, Curil K2 on case sealing surfaces etc.
Hopefully I will pick the heads up tomorrow (have had some delays at the head shop)....things are going to have to ramp up soon as warwick is
approaching fast!
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