| [ Total Views: 1509 | Total Replies: 30 | Thread Id: 38905 ] |
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 splitbusaustralia
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| posted on May 10th, 2005 at 09:26 AM |
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Getting leo's new donk running (a true and terrible tale)
Last weekend I decided to get Leo’s type 4 engine starting, running and give it a tune. The plan being I would then bleed his (new) brake system
and take him for a bit of a drive up and down the street. Estimated time was an ‘easy’ day to do the lot.
I bought a new Bosch starter for him and charged up what should have been a good battery overnight on the Friday. Woke up Saturday and went and had
coffee (large caramel latte – yum sugar and caffeine) and breakfast with the kidz at GJs in Pako….read papers in between helping kidz with Take5
magazine puzzles and daydreamed about an easy and quite satisfying afternoon getting Leo running and having a little drive (I’ve never actually
driven him).
Go home full of caffeine and sugar (as previously noted) ready to go. The battery charger’s indicator light was showing fully charged (as was I
dues to caffeine and sugar as previously noted) - sweet!
Filled new oil filter with oil and fitted. Pulled one of the lines to the remote oil cooler and filled that with oil too. No oil spills very pleased
about saving the environment. Fitted the battery and disconnected the coil lead and the electric fuel pump as the plan was to crank a bit of oil
around the engine first. Fitted a remote wire to starter so I could crank from the engine bay….already then! Put power on remote starter lead
and…
That ‘thunk’ sound you get when the starter pinion engages but doesn’t crank. Think the first relatively mild swear word for the day (mild and
not vocalising yet so everything’s still cool). Pull the starter, which is a bitch of a job because of the top starter nut on the engine bay side
is behind upright tin and a sexy weber carb (I remind myself that anything that looks really really sexy is always trouble in the long run!).
Test starter on supposedly ‘good’ battery – no spin. Hmmm my new starter is a dud or what should be a ‘good’ battery is kaput. Test
starter on the Ford’s known to be good battery. Starter spins. Ergo the supposedly ‘good’ battery is kaput. Think same relatively mild swear
word again. Go and buy new battery.
Install new battery. Refit starter (see note above on top bolt, but still OK on caffeine and sugar and haven’t barked knuckles or cut hands yet so
its still good). Go to step 1. Engine cranks, red light off, little bumpy movement on oil pressure gauge. Sweet.
Reconnect coil wire and power to electric fuel pump. Have statically timed engine and set carbs (idle mixture 2 turns out, air volume 2 turns in
after engaging lever) so expecting things to burst into life with a healthy roar and the sexy sound of weber induction roar and the whine of straight
cut cam gears (have I mentioned that I think anything that looks or sounds really really sexy is always trouble in the long run?).
Crank and ……..nada. Nada nada nada. Vocalise relatively mild swear word. Caffeine and sugar wearing off slightly at this stage. Methodically
test ignition circuit. Power to coil, power to points, points trigger test light, pull spark plug leads and test when cranking, nice spark. Conclude
ignition side OK.
Gotta be fuel. Jack leo up and pull fuel line at filter expecting it to be dry because of some fuel pump problem. Petrol pours over arm (I HATE
getting petrol on my skin – I can smell it for days!) and environment. Vocalise first swear word that’s not so mild.
Put fuel line back return to engine bay and review options. Can’t actually look down barrels of sexy webers because not enough room (but looking
really really sexy) but know I set the float levels OK and fairly sure they have petrol given its being delivered OK. Have spark. Must have (not so
mild swear word)’ed up the timing – gotta be 180 deg out. Switch plugs leads around to shift 180 degrees.
Go to step 1. Crank. And……..ACTION! Well, sounds like 2 cylinders of action combined with a massive exhaust leak on the LHS. Not the smooth
turbine like whine of a fully balanced engine…So much for the induction roar of a pair of sexy webers and the sweet whine of straight cut cam gears!
My teeth chatter as I hold the throttles and the engine jumps around. Haven’t been bumped around this much since I was last in a splitbus running
a 68/69 front beam lowered on adjusters!
Cut ignition. Ponder. Begin to worry that if I got the ignition timing 180 out I may have also got all the valve timing out when I set up the
engine. Don’t think so but (sigh) better check it. Put leo back on jack. Not a lot of room to do tappets on a type IV in a splitbus. Was
thinking I wouldn’t have to worry about it for 500 miles……think about going back to GJs for another large caramel latte, decide that’s
avoidance behaviour and press on.
Pop rocker cover and left hand side. Check valves gaps, they’re OK, #4 inlet and outlet a bit tight for some reason, bark first knuckle undoing jam
nut to reset. Pop cover on RHS and check. They’re OK. Clean rocker covers, fit new gaskets with sealer on rocker cover side (hate leaks) and
refit. Take leo of jack.
Return to engine bay. Crank again illogically expecting the turbine when really why would I since nothing has changed since the last attempted start?
Logic wins and Leo bumps’n’grinds away on two with massive LHS exhaust leak. Wind up idle so he’ll bump’n’grind by himself and check oil
pressure. 50-60 PSI cold – sweet.
Decide I better start pulling spark plug lead wires to find missing cylinders. LHS (#3 and #4) have nice healthy spark but are not ‘running’.
Hmmmmm. Ponder whether the massive exhaust leak on that side could be reflecting some sort of loss of compression. Vocalise swear word with
adjective and modifier. Can’t see how that could be but put Leo on jack and crawl underneath to look for signs of blow by. Can’t see anything
(swear word with religious overtones offering thanks…).
Hmmm. Not running on #3 and #4, but valve/ignition timing is OK, spark is good, and fuel is being delivered to the carb (but I can’t look down the
sexy weber’s throat to see what’s happening, I do like the way it looks though). Decide to pull the LHS carb and check it out.
Well I thought setting the valve clearances was going to be a bitch of a job…..
Have to pull em at the head cos you simply can’t get at one of the nuts that holds the carb to the manfold. Work the two middle head nuts off 1/32
of a turn at a time and then spend a happy half hour fishing one of the nuts out from where its dropped (and jammed which also stop the manifold
coming off). Who cares about barked knuckles and cut hands anymore? Get sexy weber and manifold off.
Getting dark now, caffeine and sugar buzz disappeared hours ago.
Dismantle carb. Both idle jets are completely blocked with crap. Must have come out of the bottom of the tank and been delivered to that carb first.
I wonder what my $15 Ryco fuel filter actually does…….
Blow the carb out and reassemble. Remember hoping that this wasn’t going to be an ongoing thing – I was always cleaning the carbs on Chrissy’d
notch when she ran it low on petrol.
Saturday was done and Leo wasn’t running.
Woke up Sunday. Took kidz down Pako for coffee and GJs and Sunday paper and Take 5 puzzles. Beginning to think I have a serious addiction here.
Have a large caramel latte and trade in my freebie card for another regular. Skip home working on a new guitar riff in my head (pity I’ve nearly
sliced the top of my left hand index finger off somewhere along the line and I won’t be able to play it for a while - I was never into the blood on
the frets thing – its rusts the strings and they’re expensive…).
Refit LHS sexy weber and manifold…see comments above re what a bitch of a job that is. Return to step 1. Crank. Leo bursts into what I assume is
fully balanced turbine like life, with sexy weber induction roar and the whine of straight cut cam gears. If I could hear it over the massive exhaust
leak on the LHS…..
Jack Leo up and pull his exhaust and LHS heater box. One of the copper exhaust gaskets is skewwiff and hasn’t seated properly. In fact its nearly
bent in half. No wonder the big exhaust leak. Clean the high temp RTV silicone off everything, fit new gaskets, silicon and reassemble. Go to step
one.
Crank. Leo burst into life sounding like a fully balanced turbine. The whine of the straight cut cam gears is serious without being too obtrusive
and the induction roar of the webers is really really quite sexy………
RobK
[Edited on 9-5-2005 by splitbusaustralia]
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frenzix
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| posted on May 10th, 2005 at 10:04 AM |
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That's excellent rob, Good to see you got those sexy bastards going... so tell us , did you take him for a spin?
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matara
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| posted on May 10th, 2005 at 10:08 AM |
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Rob, a well written excellent read.
Sometimes I find if you hide your VW engine in storage for 10-20 years or so then it will turn after a sip of petrol and 2 turns of the key.
Well thats what every barn find story appears to indicate.
I went through similar trouble in Ireland a few weeks ago with my 68 and its freshly rebuilt 1300TP. The dizzy was 180 degrees out!
Cheers
Steve
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 Bizarre
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| posted on May 10th, 2005 at 10:08 AM |
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I dont normally read long posts...... but ....sorry Rob..... that is funny :P
I think it is time for a beer now instead of the latte
Futue te ipsum!!!
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kombi_kid
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| posted on May 10th, 2005 at 10:11 AM |
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awesome mate just awesome!!! so did u get to drive leo??
i know your theory behind sexy things thats why i dont bother :P:P
cheers
rhys
it aint just cool its aircool'd
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KruizinKombi
A.k.a.: Col
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| posted on May 10th, 2005 at 10:14 AM |
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Wooohoooo!!! Well done Rob. 
Now for the drive.....
Kruizin Kol
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VWENVY
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| posted on May 10th, 2005 at 10:18 AM |
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Isnt it just beautiful when things go to plan!! 
I hope you pulled up a chair and an esky and sat there listening to the donk and the straight cut gears and looking at the sexy webber - thinking DAM
STRAIGHT!
:thumb
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Stealth
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| posted on May 10th, 2005 at 10:22 AM |
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Well done Rob, it's great to hear that it got going without too much of a hassle
Don't forget to factor in the costs of the GJ Caramel Latte's in the resto budget 
STEALTH |
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kombi_kid
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| posted on May 10th, 2005 at 10:29 AM |
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one more thing rob i also love gloria's mocha caramel late's especially with caramel around the top,cream oooooohhhhhhhh yum im going there know
it aint just cool its aircool'd
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 vw54
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| posted on May 10th, 2005 at 10:37 AM |
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Rob
That esay rates a A +
Mate the ideal way is to go get a bell housing and sit the engine on a 20L tin hook up battery and temporay fule supply and hit the starter....
MUCH EASIER to start the engine out of the car especially with carby and exhaust problems etc etc NEXT time OK n stop drink that shitty Caramel
coffee YUK
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baybuscamperkid
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| posted on May 10th, 2005 at 11:07 AM |
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so did u get to take him for a run? man i wish i had your knowledge (working on it)
Reimagined/Recycled/Upcycled Cool
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Octa
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| posted on May 10th, 2005 at 12:06 PM |
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Mate, that is a great read, and congratulations on your success.
BTW, I was laughing my #$% off when I read this:
(swear word with religious overtones offering thanks…).
It works better than actually writing the swear word.
'We teach best what we most need to learn'
VW no more... sigh.... well, at least it's a cousin  |
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57kombi
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| posted on May 10th, 2005 at 02:58 PM |
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All I can say is top story. Well written and posts like this are the main reason I keep returning to the site.
Cheers
Dave
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koolkarmakombi
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| posted on May 10th, 2005 at 07:31 PM |
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APPLAUSE
and band aids
and a double shot tall latte from zaraffa's
that should keep you going!
well done :party:party:party:party
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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Zimblewinder
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| posted on May 10th, 2005 at 07:43 PM |
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Nice read Rob. Dont know about you though... when its my own project I always feel a little ripped off if the engine starts first time. The feeling
that somehow it was all to easy and cheapened the experience... keep looking at the engine suspiciously and wondering when its going to come to its
senses... start giving me trouble (like it should....right?)
Who ever believes theyve heard the last of it when the engine is purring sweetly!! |
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ratty 63
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| posted on May 10th, 2005 at 07:44 PM |
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Awsome read - congrats on getting it running too! Makes it all seem worthwhile...
R
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Che Castro
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| posted on May 10th, 2005 at 08:23 PM |
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Heheh i dont usually read long posts either but this kept me glued to the monitor
Jon
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Notchbacktastic
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| posted on May 10th, 2005 at 08:46 PM |
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Long, too long ago are the days of old when I heard a Weber/s howl, still the memory remains.
One day, I too will realise your elation,
for webers and large caramel latte-ations!
Great read!
Rock on. |
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frank2112
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| posted on May 10th, 2005 at 09:14 PM |
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Excellent read ! Not sure which addiction is stronger - The coffee or the car.
At least I'm not the only one that has hassles when fighting /fixing my cars
Spare the Duct tape, spoil the job - Red Green
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barls
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| posted on May 10th, 2005 at 09:15 PM |
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good read mate glad t hear you got it running
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Bizarre
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| posted on May 10th, 2005 at 09:21 PM |
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Rob
how long before you cut an acess hatch in the top to get to those "sexy" webers???
Would make life much easier to clean blocked jets
Futue te ipsum!!!
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VolksFolks
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| posted on May 10th, 2005 at 09:39 PM |
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| Quote: | Originally
posted by Che Castro
Heheh i dont usually read long posts either but this kept me glued to the monitor
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like a article
nice work rob
They laugh because You are different, You laugh because They are all the same.
check out http://www.lowlight.com.au for low lights only.. |
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Dasdubber
A.k.a.: Alan Agyik
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| posted on May 10th, 2005 at 10:40 PM |
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Like all others, I'd have to agree that was an entertaining and well written post Rob...glad to see the story had a happy ending!
I know I would have degenerated into heavily vocalised multiple strings of expletives though so I think you did well to contain yourself!
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GL1972
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| posted on May 11th, 2005 at 08:57 AM |
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Great read.
You know you have got it real bad when your twin webers/dellortos are louder than your exhaust and stereo combined and you love it!
Brendan
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pete wood
A.k.a.: figure itout
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| posted on May 11th, 2005 at 03:57 PM |
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So how well does he go?
will he pull seconds?
BTW, I thought you were gonna tell us there was no oil pressure and he seized when you said sad and terrible.
[Edited on 11/5/2005 by pete wood]
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splitbusaustralia
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| posted on May 11th, 2005 at 04:20 PM |
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Nah - sorry guys. Haven't driven him yet. Still got to bleed brakes and roughly check front wheel alignment.....this weekend if time permits?
I'm not sure he'd be extremely quick over an 1/8 or 1/4 (although I would expect him to be a bit faster than yer average splitbus). He was built
with a view
to being a comfortable and fast cruiser (for a splitbus). I'd personally put a built swingaxle in a 'drag' splitbus rather than IRS it.
However, I am starting to have these weird thoughts about barney......
RobK
[Edited on 11-5-2005 by splitbusaustralia]
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kombi_kid
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| posted on May 12th, 2005 at 10:38 AM |
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oh no i dont like the idea about these wierd thoughts rob!!! please dont do it!! make him like he was out of the factory and ill drive it while u
drive the dual cab or vica cersa  kissduh
cheers
rhys
it aint just cool its aircool'd
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splitbusaustralia
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| posted on May 12th, 2005 at 10:49 AM |
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caffeine and the brain
Could fit a blower in there without cutting a thing Rhys!
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pete wood
A.k.a.: figure itout
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| posted on May 12th, 2005 at 04:23 PM |
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| Quote: | Originally
posted by splitbusaustralia
Could fit a blower in there without cutting a thing Rhys!
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Cool :thumb
you mean a leaf blower don't you....:P
But seriously, I'd love to see one of those 4AGze blowers on a 1600 or something, like fatso's motor, just EFI and intercool it.
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squizy
A.k.a.: Paul
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| posted on May 12th, 2005 at 04:46 PM |
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What a great read Rob. It does look sexy too.
Now then, are you going for a latte at Pako's and a bit of Take 5 action with the kids beforehand....and then start another thread.....?
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