Club 80-90 Forums

That wonderful feeling when it finally turns with an few little creaks!

Oldiebut goodie wrote:That wonderful feeling when it finally turns with an few little creaks!

Dunno the 1000W impact wrench makes a right old racket I never heard any creaking
You are right about the wonderful feeling

https://www.machinemart.co.uk/p/clarke- ... ct-wrench/" onclick="window.open(this.href);return false;

Holy corrosion...

Never imagined that the studs would be quite so bad!

Motivated by the dangling carrot of a Brickwerks extra discount voucher I thought I better get on with this

Need to order parts , I know what studs I need but not what bearings so need to measure up crank, but first it needs stripping.

Photographed all con rod numbers and their position first for future ref:

P1080104 by Paul_Barr, on Flickr

released con rod bolts

P1080110 by Paul_Barr, on Flickr

shells and crank journals look good, these con rods drop slowly under their own weight like one of those posh loo seats indicating low mileage after rebuild so I may just put these back after mayo is removed, I will fit standard ( non stretch) con rod bolts.

P1080111 by Paul_Barr, on Flickr

P1080113 by Paul_Barr, on Flickr

mayo blown out, I will use an air line also later but this will dissolve most of it

P1080114 by Paul_Barr, on Flickr

P1080115 by Paul_Barr, on Flickr

next to remove the bodged part of the flywheel stuck on the crank with what's left of some mashed end float shims.

Ground down the arms of a small puller to fit the gap, placed a bolt in the end of the crank as the puller thread was not long enough
P1080118 by Paul_Barr, on Flickr

P1080123 by Paul_Barr, on Flickr

P1080124 by Paul_Barr, on Flickr

measure up next

Crank measured today, it's all good and Blue crank spec.
Blue NLA so standard bearings ordered.
Only one bearing is scored from the flywheel mod, must have been some bits of shim got in, thankfully the crank is not scored.
I will measure up and compare new bearings to VW bearings so see which is best.

20170327_093239 by Paul_Barr, on Flickr

20170327_093536 by Paul_Barr, on Flickr

3 off head studs ordered too so that's the next job

Disappointing day, mayo case stud did not want to come out, tried everything including heat and freezer spray on the stud but eventually it broke off at the base.

P1080192 by Paul_Barr, on Flickr

Also found a very suspect repair, this stud was replaced before It looks like it may have been drilled through and repaired with epoxy or similar

P1080177 by Paul_Barr, on Flickr

as there are two more studs that need replacing I turned my attention to another case I have.

This case was given to me when doing WBXlog, it had almost all the studs corroded ( two are OK out of 16), I was using it for stud removal practice and I found all but one came out easily.

The last is snapped down low and my welding skills are not good enough yet ( nut keeps snapping off) but as the rest came out easily I think it's salvageable ( perhaps some welding help from what2do), expensive for a set of studs but hey ho.

It does have damage to the alternator bracket but that may be fixable

P1080194 by Paul_Barr, on Flickr

P1080190 by Paul_Barr, on Flickr

P1080183 by Paul_Barr, on Flickr

P1080196 by Paul_Barr, on Flickr

6 months have gone by, nothing has happened I have been busy enjoying the summer camping, maybe one more camping weekend left then I must crack on with this as a winter project for the tin top.
I have aquired yet another late DG from what2do's leaky shed that has suffered from the hole in the roof and I'm going to try stud extraction the old skool way.

I've just this day ordered some alum to dissolve a broken stud in a heater heat exchanger - I'll try to remember to take some pics as I have my first try.

Oldiebut goodie wrote:I've just this day ordered some alum to dissolve a broken stud in a heater heat exchanger - I'll try to remember to take some pics as I have my first try.

Good luck, I gave up
if its going to work you will be needeing lots of heat

Now the summer is over and camping has finished for me time to get engine building again.

The two late engine cases I have both have stud and case problems that I can't yet solve so I have been raiding What2dos unloved engine collection in exchange for an engine I built for him out of Ghost123s old engine.

First up was shed engine, this had been sitting in a shed with a hole in the roof so studs have some corrosion on one side that was getting wet more than I want for my DJ build.

Next up was cold frame engine, this has been sitting in a cold frame and while outside it was quite dry and so has survived, studs have some very light corrosion but I'm happy they are good enough for the DJ build.

So WBXmayo will live again..in my tintop .. ..

20171120_171159 by Paul_Barr, on Flickr

Ahem, you don't paint me in a good light. Anyone would think I'm not a lover of the wbx - it's not true, I'm just short of space, especially dry space

what2do wrote:Ahem, you don't paint me in a good light. Anyone would think I'm not a lover of the wbx - it's not true, I'm just short of space, especially dry space

what2do wrote:Ahem, you don't paint me in a good light. Anyone would think I'm not a lover of the wbx - it's not true, I'm just short of space, especially dry space

So you didn't say on another well known social media site..... 'I feel sooooo much better as I rid myself of unloved bits' ?

itchyfeet wrote:

what2do wrote:Ahem, you don't paint me in a good light. Anyone would think I'm not a lover of the wbx - it's not true, I'm just short of space, especially dry space

So you didn't say on another well known social media site..... 'I feel sooooo much better as I rid myself of unloved bits' ?

Damn, I did as well but that is not what I meant. I was relieved that they were going to a home that had more time and resources to afford them the love they deserve...