Itinerant Air-Cooled

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?

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.

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

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..

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

It strikes me as akin to having your appendix removed as a precautionary measure.

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?

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

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

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

So here's an update.....

The engine case with the questionable bearing saddle gap was cleaned up and shipped to European Motorworks in Hawthorne, CA. They thought they might be able to salvage it. Despite being very well packed, it was apparently dropped in shipment and the oil breather section of the case was broken off upon arrival. Luckily, the insurance will nearly cover the cost of one of their align-bored cases with threaded oil gallery plugs.

The crank and connecting rods are also with them for inspection and rework. I'll be buying all bearings, a new stock cam, cam gear, and hydraulic lifters from them also.

Meanwhile, I'm collecting other parts:
- New Brazilian Mahle Pistons and Cylinders from Bus Depot
- New Flywheel and main seal from GoWesty
- New Clutch disc and pressure plate from Bus Depot

I missed out on the last pair of Len Hoffman Blueprint Special heads on the shelf by one day. I'm on his waiting list for the next batch.

vwlover77 wrote: ↑

Sun Dec 29, 2019 8:19 am

So here's an update.....

The engine case was dropped in shipment and the oil breather section of the case was broken off upon arrival.

Len Hoffman Blueprint Special heads waiting list.

I am agog.
Me too.
ColinInAtlantaFor20Minutes

I bought a new Luk clutch kit and a new GoWesty flywheel. It it worth having them balanced for a stock engine?

Yes, if you plan to drive above idle. Are the GoWesty flywheels the same new Chinese flywheels that other outfits are selling? I talked to Jose at DPR about them, and he said they were acceptable, but most still required balancing to get into factory balance tolerance.

Robbie

asiab3 wrote: ↑

Mon Jan 06, 2020 2:13 am

Are the GoWesty flywheels the same new Chinese flywheels that other outfits are selling? I

Yes, I believe so. I will plan on having it balanced along with the pressure plate assembly.