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New Type 4 VW build http://gemellocattivo.com/forum/viewtopic.php?f=2&t=325 |
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Author: | mk e [ Wed Jan 05, 2022 12:48 pm ] |
Post subject: | Re: New Type 4 VW build |
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? |
Author: | MerlinTech [ Wed Jan 05, 2022 3:14 pm ] |
Post subject: | Re: New Type 4 VW build |
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. |
Author: | MerlinTech [ Sun Jul 10, 2022 7:05 pm ] | ||||||||
Post subject: | Re: New Type 4 VW build | ||||||||
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
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Author: | mk e [ Mon Jul 11, 2022 7:25 am ] |
Post subject: | Re: New Type 4 VW build |
Looks good and its good to see SOMEONE working on an engine |
Author: | mk e [ Mon Jul 18, 2022 9:40 am ] |
Post subject: | Re: New Type 4 VW build |
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 |
Author: | MerlinTech [ Mon Jul 18, 2022 1:14 pm ] |
Post subject: | Re: New Type 4 VW build |
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. |
Author: | mk e [ Mon Jul 18, 2022 1:49 pm ] |
Post subject: | Re: New Type 4 VW build |
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 |
Author: | MerlinTech [ Wed Jul 20, 2022 7:19 am ] | ||||
Post subject: | Re: New Type 4 VW build | ||||
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.
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Author: | MerlinTech [ Thu Aug 11, 2022 7:42 am ] | ||||||||
Post subject: | Re: New Type 4 VW build | ||||||||
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.
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