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Which means "Evil Twin". Lets see your projects where you change boring into fun or create the fun from scratch.
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 Post subject: Re: New Type 4 VW build
PostPosted: Wed Jan 05, 2022 12:48 pm 
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Nice to see it progressing again!

I see what appears to be corrosion on the cases so before you get much further I do feel compelled to ask about what is your plan to address that?


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 Post subject: Re: New Type 4 VW build
PostPosted: Wed Jan 05, 2022 3:14 pm 
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It was painted black and has been cleaned and then plastic blasted. It will get hand work to make it better. It is not clean yet but it is good enough for mock up. It is an aluminum case, not MAG so that helps too. I have some welding to do to repair some of the sheet metal bolt holes.
It has a way to go before it is assembly worthy.

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 Post subject: Re: New Type 4 VW build
PostPosted: Sun Jul 10, 2022 7:05 pm 
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Time for a little update:
Full mock up is done. List of things to do is much shorter.
Saturday I spent trying to understand the oil cooler bypass system. Basically it is a spring plunger that moves out of the way and lets the oil pass the cooler passages. I have a stand alone oil cooler and an inline thermostat. I am controlling oil temp with temp, not pressure. I measured the spring and it was about 32 lbs before coil bind. Maybe 10 at the distance needed to bypass. So basically it is bypassing all the time. I machined plugs for the passages that needed them and a block plunger to seal the bypass unit. I then had to machine the end of the passages for pipe plugs to seal it all back up. Then I have mock assembled the thing. Modified the left header to allow for the bitchin valve covers that the pipe was hitting. Checked the pushrod length and looked up cut to length rods. $140.00 ish. I am happy with the deck height, I will fine tune that later, it clears now with .090 cylinder shims. Cam fits, need to fine tune the fit of the oil pump that runs off the can gear end of the cam and was hitting the cam bolts. I have some tin work to do on the cooling tins, crack, broken off bits, modification for no on block oil cooler. I am missing one piece for the right side, I need to find that.
Still need to sort all of the studs, bolts and nuts that hold it all together. The big stuff is sorted but the little bolts and studs are still a to do.

To Do:
Sort and repair tin work
Order pushrods
Finalize the seats and guides
Under cut the rest of the intake stems
Pick the head gasket to use (just a shim, not Mark level head gasket)
Disassemble and clean everything
Set ring gap
Double check all oil clearances
Shim oil pick up stand

ASSEMBLE


Attachments:
File comment: Welded in oil passage blocking
image12.jpeg
image12.jpeg [ 51.87 KiB | Viewed 4150 times ]
File comment: Head studs cleaned and blackened
image10.jpeg
image10.jpeg [ 48.55 KiB | Viewed 4150 times ]
File comment: Port match is not bad
image7.jpeg
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File comment: Scat extended sump
image5.jpeg
image5.jpeg [ 49.76 KiB | Viewed 4150 times ]
File comment: Header redo
image3.jpeg
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File comment: Valve train
image1.jpeg
image1.jpeg [ 42.96 KiB | Viewed 4150 times ]
File comment: Over all mock up
image0.jpeg
image0.jpeg [ 49.83 KiB | Viewed 4150 times ]

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 Post subject: Re: New Type 4 VW build
PostPosted: Mon Jul 11, 2022 7:25 am 
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Looks good and its good to see SOMEONE working on an engine :oops:


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 Post subject: Re: New Type 4 VW build
PostPosted: Mon Jul 18, 2022 8:02 am 
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Posts: 420
Decided that the crappy bottom for the extended oil sump would just not do. So, I made a new one. The digital read out on my mill has a setting for circle patterns and I dialed it in and the holes were spot on. Very cool feature that I had not used before. I will use that again.


Attachments:
File comment: Crap stamped steel bottom that just won't work for me.
Crap pan bottom.jpg
Crap pan bottom.jpg [ 99.06 KiB | Viewed 4120 times ]
File comment: How can this drain well? It can not, will always leave oil and sludge on the bottom.
Crap pan bottom under side.jpg
Crap pan bottom under side.jpg [ 98.17 KiB | Viewed 4120 times ]
File comment: Stock screen along with my modified pick up tube. The stock tube had a huge bell and an 8mm stud through the middle of the pick up tube. How can that be good for oil flow? Cut all that away and welded on a tube that fits the stock Type 1 bug screen.
Screen and pick up tube.jpg
Screen and pick up tube.jpg [ 90.93 KiB | Viewed 4120 times ]
File comment: New billet bottom. Who doesn't like billet?
New pan bottom.jpg
New pan bottom.jpg [ 91.89 KiB | Viewed 4120 times ]
File comment: With a taper to drain well.
New pan bottom underside.jpg
New pan bottom underside.jpg [ 80.5 KiB | Viewed 4120 times ]

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 Post subject: Re: New Type 4 VW build
PostPosted: Mon Jul 18, 2022 9:40 am 
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Fancy!

I've seen the button for hole pattern on my DRO but never used it because it would mean learning something new...perhaps its time :?


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 Post subject: Re: New Type 4 VW build
PostPosted: Mon Jul 18, 2022 1:14 pm 
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It was easy. I started at the center of the piece. Dialed in the diameter, The angle of the first hole, the angle of the last, and how many holes. Hit go and the DRO put up the numbers for hole 1, finished that and hit go for hole 2 and so on.

It will do a line of holes at an angle as well, I have done that. It does way more than I can do. It can do an outside radius too. I may try just for kicks.

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 Post subject: Re: New Type 4 VW build
PostPosted: Mon Jul 18, 2022 1:49 pm 
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MerlinTech wrote:
I can do. It can do an outside radius too. I may try just for kicks.

I wonder if mine does that? I usually blue, scribe, eyeball mill to the line


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 Post subject: Re: New Type 4 VW build
PostPosted: Wed Jul 20, 2022 7:19 am 
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Another piece of the puzzle comes together. I needed to replace the cover on the bottom of the engine. This part had my oil temp sender but was poorly made and leaked. I made a new cover. It is stepped on the underside for O-ring sealing. The sender will be installed in the extended oil sump.


Attachments:
File comment: Old leaking cover
Old leaking cover.jpg
Old leaking cover.jpg [ 120.79 KiB | Viewed 4106 times ]
File comment: Old vs new
All done.jpg
All done.jpg [ 96.79 KiB | Viewed 4106 times ]
File comment: All new and shiny
New shiny cover.jpg
New shiny cover.jpg [ 100.15 KiB | Viewed 4106 times ]

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 Post subject: Re: New Type 4 VW build
PostPosted: Thu Aug 11, 2022 7:42 am 
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I purchased an adjustable timing gear seat but the cam gear only cam with straight up washers. I contacted the company and they said they don't have the offset washers and probably won't for some time. So, I realized I have a mill, lathe, & some skill so I made some. I made the washer stock first, then a tool to hold them for facing and machining. I had to retard my cam 6 degrees to get the proper 108CL. I then made a set screw with a point and 4mm hex to transfer the hole location to the washer. Punched the washer in place and machined the first one. It was spot on. Machined the other four and then gun blued them just for good measure. Installed them, loctite and torque. Cam timing is done.


Attachments:
File comment: Facing the washers.
1.jpg
1.jpg [ 52.66 KiB | Viewed 3961 times ]
File comment: Transfer punch in place.
2.jpg
2.jpg [ 49.15 KiB | Viewed 3961 times ]
File comment: Transfer punch and 4mm socket.
7.jpg
7.jpg [ 141.72 KiB | Viewed 3961 times ]
File comment: Dimpled washer. I used an optical center punch to get the mark spot on and have a nice punch mark to center on in the mill.
4.jpg
4.jpg [ 116.21 KiB | Viewed 3961 times ]
File comment: The tool and washers.
5.jpg
5.jpg [ 126.89 KiB | Viewed 3961 times ]
File comment: Used a mill to get a really nice round hole.
6.jpg
6.jpg [ 67.91 KiB | Viewed 3961 times ]
File comment: All done.
8.jpg
8.jpg [ 130.16 KiB | Viewed 3961 times ]

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