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> Volkswagen Motor Build, Documentary
moe
post Aug 15 2008, 04:04 PM
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Nice.
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Mitlov
post Aug 15 2008, 06:11 PM
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QUOTE(fiber optic @ Aug 6 2008, 01:26 PM) *
I've been beating myself up over this for the past week while trying to make it work. I have very little patience and get frustrated easily.


I feel for ya. I don't do my own maintenance, not only because I would likely damage the car in the process, but because I would likely give myself an ulcer in the process. These sorts of things just stress the shit out of me.
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fiber optic
post Aug 16 2008, 10:57 AM
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QUOTE(Mitlov @ Aug 15 2008, 09:11 PM) *
I feel for ya. I don't do my own maintenance, not only because I would likely damage the car in the process, but because I would likely give myself an ulcer in the process. These sorts of things just stress the shit out of me.


Well, the advantage I have with the VW is that I don't have to rely on it to get me to work on Monday. I'm not in any sort of rush to get it together which does help. Working on my truck or the Volvo is a little more stressful for that reason. The work isn't hard but it does require a certain level of knowledge to not screw anything up and cheap parts certainly don't help.


Next step for the motor is to put the rods on the crank and drop the crank into the case. I think I might buy a new camshaft too, they're relatively cheap and I'm trying to hit 100HP in this thing.
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Phix
post Aug 16 2008, 02:19 PM
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Man, where did you learn to cook a gear in soybean oil to make it expand?
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fiber optic
post Aug 17 2008, 04:04 PM
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QUOTE(Phix @ Aug 16 2008, 05:19 PM) *
Man, where did you learn to cook a gear in soybean oil to make it expand?


It's the method described in the official VW service manual. smile.gif


Here's the entire assembly. Brass gear is the distributor drive. #4 bearing is really little. Dish is the oil slinger to keep oil from coming out at pulley end.


Here's the green oil. I dipped the paper towel in there. I don't know what my fixation is with the oil. It stinks something fierce though, must be all that good ZDDP.
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fiber optic
post Aug 20 2008, 03:17 PM
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Yes, progress has been slow. I was hoping the rods would just go on and everything would be giggles and pie. That was not the case. The side clearance was too tight, probably about half of what is considered the minimum for a street performance motor. Getting the clearance correct has been an exercise in repetition. Install rod, check clearance, remove rod, reassemble rod, clearance, disassemble rod, install and recheck clearance, rinse and repeat. I've done 2 rods so there are 2 more to go. I'll probably get those done tomorrow now that I've got a good method for it.


Kinda hard to read but the feeler gauge is 0.014" which is good to go. Side clearance is exactly what it sounds like. The clearance between the side of the rod and the crankshaft. Too tight and there's too much friction, too loose and all of the oil flows out, so it has to be in the sweet spot of 0.014" and 0.016" for new rods. The acceptable range for a stock motor is much larger FYI.
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fiber optic
post Aug 26 2008, 02:17 PM
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One on and torqued down. No hangups and clearance is gooooooood.
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Aircooled
post Aug 26 2008, 02:46 PM
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Ahh, don't parts look so pretty when they're brand new....

And Craftsmen tools thumbs_up.gif
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fiber optic
post Aug 27 2008, 03:28 PM
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Note the notch on the right side of the rod. The cap also has one and they are there so you put them on against each other. The rod has some kind of offset in it and this makes sure you get it the right way. Notches go toward the camshaft.


Here's the crank assembly sitting in the left case half.
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fiber optic
post Aug 29 2008, 03:47 PM
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I was going to mock up my old camshaft in the case but I ran into a problem.


The spot for the large thrust bearing has no notch.


The bearing has a tang on it that won't fit.


So I filed it off. The other way to go is to notch the case but the cam bearings are cheap compared to the case if I screw it up.

I'll drop it in tomorrow and see if I'll need to get my new cam clearanced. It's possible the throws on the crank could hit the cam. I figure I'd try with my old cam so when I order the new one I can have the shop clearance it before they send it.
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fiber optic
post Aug 30 2008, 12:29 PM
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Crankshaft and camshaft installed in the case.


I'm glad i checked this because this is way too tight. The distance between the rod and the camshaft thrust surface was only 0.006". I didn't think about this area being a problem and the spots I thought might have been weren't. Check, check, and re-check.
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Aircooled
post Aug 30 2008, 09:52 PM
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What lifters are you running?
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fiber optic
post Aug 31 2008, 04:49 AM
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QUOTE(Aircooled @ Aug 31 2008, 12:52 AM) *
What lifters are you running?


I'll probably buy a set of Gene Berg's when I buy the new cam.
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fiber optic
post Aug 31 2008, 12:53 PM
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I was going to change the coolant on the Volvo this afternoon but like an idiot I forgot to get distilled water. Instead I did some work on the VW motor.


Distributor drive pinion play. Minimum is 0.020" and I'm measuring at least 0.035".
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Benny
post Aug 31 2008, 07:10 PM
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I wish I knew what most of this meant, but whatever, it sure is exciting to see this progress fiber!
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fiber optic
post Sep 1 2008, 11:44 AM
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QUOTE(Benny @ Aug 31 2008, 10:10 PM) *
I wish I knew what most of this meant, but whatever, it sure is exciting to see this progress fiber!


I'll tell you what, I don't even know what the point of the previous measurement is!

It is good for me to finally make some progress on this thing after such a long time. Everything is taking 3-4 times longer to do than I expected. I guess in the back of my head I thought I'd just be slapping parts together and checking to make sure clearances are OK and progress would be pretty quick. Ha! It's been a good learning experience though.
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Synesthesia
post Sep 1 2008, 12:16 PM
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QUOTE(fiber optic @ Sep 1 2008, 03:44 PM) *
It is good for me to finally make some progress on this thing after such a long time. Everything is taking 3-4 times longer to do than I expected. I guess in the back of my head I thought I'd just be slapping parts together and checking to make sure clearances are OK and progress would be pretty quick. Ha! It's been a good learning experience though.


Ahhh...life. smile.gif Would you mind explaining how you go about getting your parts machined? How does it not cost a fortune? How do you describe exactly what you want done with all these little weird parts?
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fiber optic
post Sep 1 2008, 02:03 PM
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QUOTE(Synesthesia @ Sep 1 2008, 03:16 PM) *
Ahhh...life. smile.gif Would you mind explaining how you go about getting your parts machined? How does it not cost a fortune? How do you describe exactly what you want done with all these little weird parts?


"All these little weird parts" are standard on these motors. My motor is fairly tame in comparison to the monsters some people have built. I've been buying the parts machined as needed. For instance when I bought the case I had them clearance it to clear the longer stroke of the crankshaft. Not a big problem really.
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Phix
post Sep 1 2008, 03:12 PM
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Soybean oil. Expansion.

WOW!
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fiber optic
post Sep 2 2008, 01:22 PM
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I was cleaning up my little work area a bit and forgot about these plugs. There are 4 of them that I took out when I was cleaning the crankshaft. Without these there's no oil pressure so they are very important.


Blue loctite to keep them in place while the crankshaft spins.
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