Don's (vwlover77's) Engine Build

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vwlover77
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Don's (vwlover77's) Engine Build

Post by vwlover77 » Tue Nov 12, 2019 10:00 am

I'll use this thread to document my adventures, and ask many stupid questions, for my (mostly) new engine build. It's going to be a stock 2.0L hydraulic lifter engine.

I have obtained a GD engine case that seems to be in good condition.

The first questions are: Which of the original oil gallery plugs should be replaced with threaded plugs? ALL 11 of them, or just a subset? And is this something I dare undertake myself, or should I leave it to a machine shop?
Don

---------------------------
78 Westy
71 Super Beetle Convertible Autostick

"When we let our compassion go, we let go of whatever claim we have to the divine." - Bruce Springsteen

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SlowLane
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Re: Don's (vwlover77's) Engine Build

Post by SlowLane » Tue Nov 12, 2019 2:34 pm

vwlover77 wrote:
Tue Nov 12, 2019 10:00 am
The first questions are: Which of the original oil gallery plugs should be replaced with threaded plugs? ALL 11 of them, or just a subset? And is this something I dare undertake myself, or should I leave it to a machine shop?
FWIW, I left the original stock gallery plugs alone when I did my rebuild. Just swabbed them with a thin coat of JB Weld, which I expect will do absolutely nothing to prevent them from loosening if they are determined to come loose, but it seemed like a good idea at the time.

So far, no issues. I'm in the "Ain't broken? Don't fix." camp on things like cutting threads in case bores that weren't sized for standard thread sizes to begin with.
'81 Canadian Westfalia (2.0L, manual), now Californiated

"They say a little knowledge is a dangerous thing, but it is not one half so bad as a lot of ignorance."
- Terry Pratchett

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satchmo
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Re: Don's (vwlover77's) Engine Build

Post by satchmo » Wed Nov 13, 2019 8:47 am

When I built my 2.0, I had Rocky Jennings (https://www.thesamba.com/vw/classifieds ... id=1107153) do the oil gallery plugs. I don't recall how many there were, but I don't think it was 11. Five or six maybe. He had all the jigs for drilling and tapping (I think he may sell them to DIY folks), and he does this routinely as part of any engine build he does.

Satchmo
By three methods we may learn wisdom:
First, by reflection, which is noblest;
second, by immitation, which is easiest;
and third, by experience, which is bitterest. -Confucius

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tommu
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Re: Don's (vwlover77's) Engine Build

Post by tommu » Wed Nov 13, 2019 9:21 am

Someone on the Samba there's a diagram showing which get drilled and how. Personally I wish I hadn't had mine drilled. The machine shop I used did a bad job..

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Amskeptic
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Re: Don's (vwlover77's) Engine Build

Post by Amskeptic » Wed Nov 13, 2019 4:39 pm

I am of the Leave Them Alone School, after they pass a close visual test for any evidence of leakage.

A good thread/tap job is nice, but I have seen several disasters.

I did lose a flywheel end gallery plug in 2002. I never did thread that hole, just slammed the old gallery plug back in with JB Weld. It lasted 7 years and 150,000 miles. I would not recommend that to anyone, it is just a fact that a careful prep and JB Weld job can be done in a laundromat parking lot with interested bystanders ...
Colin
BobD - 1978 Bus . . . . . . . . . . . 112,660 miles
Chloe - 1970 bus . . . . . . . . . . . 206,845 miles
Naranja - 1977 Westfalia . . . . . 112,885 miles
Pluck - 1973 Squareback . . . . . . 55,570 miles
Alexus - 1991 Lexus LS400 . . . 78,899 miles

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SlowLane
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Re: Don's (vwlover77's) Engine Build

Post by SlowLane » Fri Nov 15, 2019 12:11 pm

It strikes me as akin to having your appendix removed as a precautionary measure.
'81 Canadian Westfalia (2.0L, manual), now Californiated

"They say a little knowledge is a dangerous thing, but it is not one half so bad as a lot of ignorance."
- Terry Pratchett

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airkooledchris
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Re: Don's (vwlover77's) Engine Build

Post by airkooledchris » Fri Nov 15, 2019 4:02 pm

vwlover77 wrote:
Tue Nov 12, 2019 10:00 am
I'll use this thread to document my adventures, and ask many stupid questions, for my (mostly) new engine build. It's going to be a stock 2.0L hydraulic lifter engine.

I have obtained a GD engine case that seems to be in good condition.

The first questions are: Which of the original oil gallery plugs should be replaced with threaded plugs? ALL 11 of them, or just a subset? And is this something I dare undertake myself, or should I leave it to a machine shop?
What are you going to do with the case before moving forward? Get it measured so you know what bearings to use? Does it need or has it already had an alignbore?
1979 California Transporter

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Amskeptic
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Re: Don's (vwlover77's) Engine Build

Post by Amskeptic » Sat Nov 16, 2019 8:19 am

airkooledchris wrote:
Fri Nov 15, 2019 4:02 pm
vwlover77 wrote:
Tue Nov 12, 2019 10:00 am
I'll use this thread to document my adventures, and ask many stupid questions, for my (mostly) new engine build. It's going to be a stock 2.0L hydraulic lifter engine.

I have obtained a GD engine case that seems to be in good condition.

The first questions are: Which of the original oil gallery plugs should be replaced with threaded plugs? ALL 11 of them, or just a subset? And is this something I dare undertake myself, or should I leave it to a machine shop?
What are you going to do with the case before moving forward? Get it measured so you know what bearings to use? Does it need or has it already had an alignbore?
We have been discussing the need to clean, to torque up, and measure the case saddle bores. The fastest way to determine alignbore is to put a boring bar through the saddles and see if all rotates smoothly.
Colin
BobD - 1978 Bus . . . . . . . . . . . 112,660 miles
Chloe - 1970 bus . . . . . . . . . . . 206,845 miles
Naranja - 1977 Westfalia . . . . . 112,885 miles
Pluck - 1973 Squareback . . . . . . 55,570 miles
Alexus - 1991 Lexus LS400 . . . 78,899 miles

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asiab3
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Re: Don's (vwlover77's) Engine Build

Post by asiab3 » Sat Nov 16, 2019 9:26 am

Don, you recently posted pictures of your case on the samba along with some questions about the #1 bearing saddle. I’m on my phone so pardon the fact that I’m not quoting and highlighting...

With the amount of crud in the bell housing, I wouldn’t even break out the tools until the whole thing is CLEAN. Someone suggested using a file to clean the edges.... Metal removed can not be put back, so it’s worth taking the time to thoroughly clean the works before making a judgement call on machining.

My two cents,
Robbie
1969 bus, "Buddy."
142k miles with me.
319k miles on Earth.

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vwlover77
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Re: Don's (vwlover77's) Engine Build

Post by vwlover77 » Sun Nov 17, 2019 6:10 am

The cleaning is in-process now. What a MESS!!! No abrasive or file of any type shall touch any machined mating surface!
Don

---------------------------
78 Westy
71 Super Beetle Convertible Autostick

"When we let our compassion go, we let go of whatever claim we have to the divine." - Bruce Springsteen

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