My Fourth Engine Build

[ruckman101]

Gorgeous day up here on Dunnigan Mountain. A peanut gallery is always welcome. You could give me feedback on my third brew.

46806 NE Tie Pond Road. Amboy, WA

https://maps.google.com/maps?client=saf ... CCwQwwUwAA

neal

[ruckman101]

"Don't over-think this," sez Colin.

'Tis my nature, especially striving to get everything just exactly perfect. So I'm back to the longer spring for the oil pressure relief valve. This is a dual relief case, which began '70/'71, which Bentley specs as higher pressure at load height of 12.3 to 16.0 lbs at 1 3/4", v 5.5 to 9.2 lbs at 1 11/16". Paired with a slightly stiffer pressure control spring.


neal

[ruckman101]

Woo-hoo! Got the case together today. Everything seems dandy. Tight, but smooth.


neal

[Amskeptic]

Woo-hoo! Got the case together today. Everything seems dandy. Tight, but smooth.


neal

Congratulations. Define "tight" but smooth . . . . Hey, retorque every case bolt after a couple of days, just a good thing to do.
Colin

[ruckman101]

Takes some effort the turn it, but consistent all the way, no catching, lurching, variance. And yes, will be retorquing.

Major annoyance today. Thought I had an oil pump but the backlash is terrible and one gear is taller than the other, and a good .008 gap between them and the cover plate. Out of the five, the best one in terms of backlash is for a case with 8mm oil galleys. Found a decent one, but the gears are only 21 mm, not the 26 mm I thought I had. And confusion. No mention of gears that dimension. 19 and 24 mm.

Dang it. Still waiting on the heads.


neal

[Amskeptic]

Takes some effort the turn it, but consistent all the way, no catching, lurching, variance. And yes, will be retorquing.

Major annoyance today. Thought I had an oil pump but the backlash is terrible and one gear is taller than the other, and a good .008 gap between them and the cover plate. Out of the five, the best one in terms of backlash is for a case with 8mm oil galleys. Found a decent one, but the gears are only 21 mm, not the 26 mm I thought I had. And confusion. No mention of gears that dimension. 19 and 24 mm.
Dang it. Still waiting on the heads.
neal

Welcome to the maddeningly incremential development of air-cooled Volkswagens . . .
Colin

[ruckman101]

Well life happens and not much to update. Bon Ami scoured my jugs after the tedium of filing out casting slag. Much tougher stuff than the same task on heads.





There is still a nasty wide huge bit of slag I gave up on. About a one and a half or two mm aberration from concept, but about half an inch across. So a compromise. Hopefully minor.

A couple photos to catch up some. Bottom bottom end finally coupled.



At the kitchen table chasing used hardware thread with tap and die.



I have no clue, but this was there on my p/c set.



Here's the drive gear to the oil pump I didn't use after checking it for tolerance between gear and cover plate and gear lash. Failed on both accounts.



Today the new oil pump begged for longer studs to mount. Made sure they weren't so long the mustache bar would be compromised.

Heads are out of the shop. Further.



neal

[Amskeptic]

Well life happens and not much to update.

neal

Hit the cylinder barrel casting flash with a dremel cutting wheel.

Oil pump drive gear is a press fit on the shaft. You can set distance to bottom of oil pump cavity. You can then file the oil pump body down on the outside a tad to get your gear-to-cover allowance within spec. You can also file the cover plate to get rid of any scores. Excessive lash is the only thing that I cannot compensate for. Definitely get the oil pump studs short as possible to just stick out past the nuts, Those studs can mess up the crank pulley tin, then all hell breaks loose when you start the engine and hear the pulley rubbing against the tin. I gots that tee shirt.
Colin

[vistacruzer]

sanding the oil pump wet/dry on a sheet of glass.

[ruckman101]

Fins are too tall for the dremel at that spot. New pump specs out.


neal

[vistacruzer]

I used a sawzall with a long blade to clear the fins on my heads

[hambone]

Oh Colin shame on you.

[Amskeptic]

Oh Colin shame on you.

You don't even know . . .
Colin
(bashing that b*tch with a 2X4 destroying my pretty paint job because I hadn't noted the oil pump studs . . . shame is too good a word to waste on my dumb-b-b-ba$$)

[ruckman101]

Ok, the oil pump studs may be a tad long. They touch the tin. I'm loath to pull the pump, but will grind/cut them back a touch. Wanted to be sure to have enough thread for the nuts, and patted myself on the back for replacing the original studs with longer ones rather than backing out the ones there enough. The longer ones set deeper into the case than the shorter ones even in their original position.


neal

[hambone]

I went thru that too with a customer's engine, oops. Just threaded the studs in further, but you may not be able to..