Itinerant Air-Cooled

Step 1: Come to the realization that I would really like a quiet exhaust system, and an engine that I would feel comfortable driving further than 200 miles from home. (Heads are toast, not even rebuildable)

Step 2: Wife convinces me to go ahead and spend the $$$ on a set of Len heads because the bus isn't leaving the family for a very, very long time (she threatened me w/ divorce if I sold it).

Step 4: Pull engine from bus, post pics on line. Receive feedback that it looks like it has oil blow by, so should at the minimum replace rings and hone cylinders.

Step 3: Ehhh, If I'm going through all this effort, should probably replace P's and C's...order a set of Mahle's.

Step 4: Colin comes over and takes a look at it. The bump stick is toast. You gotta crack the case.

Step 5: Get a bit of the deer in the headlights feeling with all the work that is ahead.

Step 6: Several weeks later order Tom Wilson's book

Annnd, this is where it's at. This isn't going to be one of those really cool posts with lots of pics, and detailed instructions (I'm not that patient). It will most likely turn into a place for me to rant and vent a bit and ask for advise. But, hopefully someone will eventually find some nuggets in it.

Stay tuned...Wilson book comes in a week or so, and I've still got to finish tearing down the engine. and oh yeah, have a LOT of cleaning to do!

I'm ahead of you as I am reassembling my 914 motor today. Well, atleast buttoning up the case as the gasket set came and I have a new rear main custom fit to solve that problem. Cleaning is done!

TrollFromDownBelow wrote: ↑

Sun Sep 09, 2018 6:16 pm

oh yeah, have a LOT of cleaning to do!

Oh yes, you do . . .
ColinDawnSalesman

I found a case half would fit nicely in one of these in the bath tub:



These bottle brushes helped too. And they're not brass.. https://www.harborfreight.com/9-piece-t ... 90631.html

tommu wrote: ↑

Mon Sep 10, 2018 9:16 pm

I found a case half would fit nicely in one of these in the bath tub:

Nice! I used a milk crate to hold the Dining Room Engine in the Road Warrior.

Never pass up a good photo opportunity during the process...

Robbie

asiab3 wrote: ↑

Tue Sep 11, 2018 10:46 pm

Never pass up a good photo opportunity during the process...

Robbie

Nice pic! although it would be more interesting to see the pistons too, to see if you had dropped them on the concrete.

TrollFromDownBelow wrote: ↑

Fri Sep 14, 2018 7:07 pm

Nice pic! although it would be more interesting to see the pistons too, to see if you had dropped them on the concrete.

How rude . . .

I have the photographs of what pistons look like when they are dropped on concrete, and yes, it is very very interesting:




Now, isn't that interesting?

Yeah, so is this one, you know, where you were trying to fish out your contact lens from the lifter bore?

Touche my friend. Although when did they start making contact lenses out of ferrous metals?

I have started the Wilson book. Skipped the 'does it need to be rebuilt?' Yup. And 'how to pull your engine' section (done that). Skimmed the parts interchange section for the Type IV bits, and am more closely reading the tear down part.

See, I told you this thread would be a hoot.

TrollFromDownBelow wrote: ↑

Wed Sep 19, 2018 4:56 pm

See, I told you this thread would be a hoot.

A veritable barrel of laughs so hard I almost piston myself.

Read this just to see if you might have any issues while the engine is out. Procedure comes later:

viewtopic.php?f=47&t=13694

Everybody with a bus has a chance for a quieter experience.
Colin

Finished reading the tear down section of Wilson, and half-way through the rebuild section; at least have the pertinent sections hi-lighted. Plan on spending quality time finishing the tear down this weekend.

EDIT:

The purpose of me posting is to (hopefully!) show that someone with a modicum of experience can successfully rebuild one of these things. This won't be engine porn with beautiful picks, but it will contain from time-to-time some picks in my working-man's garage (no epoxy floor here, but does have a protective coating of random oil stains) in various stages.

“Welcome to rebuilding Volkswagen engines, where the abilities to look, measure, clean, and PAY ATTENTION, are far more important than experience.”

Shops with “experience” are exactly why I had to build my own years ago. And I don’t think it’s their fault, partially due to parts quality continuing to decline; building your own in your hobby/free time is the only financially viable way to get it done right for an economical sum.
Robbie

I am now down to the "moment of truth" splitting the cases. I did the double tap method for a bit, but think I'm going to have to refanagle the cases so that only one side (the right side) is attached to the engine stand vs both. Will probably even post a pic for all to look and see. If not this weekend, then hopefully next.

TrollFromDownBelow wrote: ↑

Sat Mar 23, 2019 4:35 pm

I am now down to the "moment of truth" splitting the cases. I did the double tap method for a bit, but think I'm going to have to refanagle the cases so that only one side (the right side) is attached to the engine stand vs both. Will probably even post a pic for all to look and see. If not this weekend, then hopefully next.

A nice soft pine 2 X 4 can help you separate the case halves. Tap the "loose half i.e. not the engine stand half) at the oil pump bore and the strainer hole. Be very very sure that you have the center 13mm bolt out of the left half that hides between #3 and #4 lifter bores.
Colin

Some pics of the split case...FWIW - I couldn't get the image to appear, only a clickable link..

https://drive.google.com/file/d/0B6n1ie ... sp=sharing

https://drive.google.com/open?id=0B6n1i ... BnMFBsVnI0

https://drive.google.com/open?id=0B6n1i ... NreVFFSDBR

https://drive.google.com/open?id=0B6n1i ... NrN0JVZzNz

https://drive.google.com/open?id=0B6n1i ... NGR1o3U2Uw

https://drive.google.com/open?id=0B6n1i ... E5eFNtME13

https://drive.google.com/open?id=0B6n1i ... NEWEFJTjJz

https://drive.google.com/open?id=0B6n1i ... 42NVVuaGVv

Case and crank seem to be in pretty good shape. Clearance between the connecting rods varied between .013 to .017 - only one was at .017... well within the wear limit, so will probably reuse. Hoping that the crank can be just polished.

Thoughts on the pics?