WBXOily

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Re: WBXOily

Postby itchyfeet » 09 Feb 2018, 18:15

shopping list, £275 already for a top end refresh ( without labour) , I'm sure I will think of something else...

0.4mm shim
https://www.brickwerks.co.uk/t3-parts/e ... 0-4mm.html

0.32mm shim
https://www.brickwerks.co.uk/t3-parts/e ... -3542.html

99289 Speedi sleeve
http://www.ebay.co.uk/itm/99289-SKF-Spe ... 2281057745

VR Full gasket set
https://www.vwheritage.com/025198009b-g ... t-vw-spare

x4 DG piston ring sets
https://www.brickwerks.co.uk/t3-parts/e ... dh-cu.html

8x telescopic push rod tubes ( we binned the originals)
https://www.vwheritage.com/ac1094109a-s ... e-vw-spare
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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Re: WBXOily

Postby itchyfeet » 12 Feb 2018, 19:34

Cleaned up pistons and barrels tonight

This is common, green oring is unrecognizable

ImageP1090532 by Paul_Barr, on Flickr

this one won't even dig out so a quick blastt of the blow torch does the trick

ImageP1090533 by Paul_Barr, on Flickr


cleaned up with a nylon wheel

ImageP1090536 by Paul_Barr, on Flickr

honed

ImageP1090537 by Paul_Barr, on Flickr

No 3 has had it along with No 3 piston

ImageP1090540 by Paul_Barr, on Flickr

ImageP1090539 by Paul_Barr, on Flickr

No1 barrel is also IMO scrap, it sealed before but you have to wonder who put this back


ImageP1080792 by Paul_Barr, on Flickr

other pistons cleaned up OK

ImageP1090541 by Paul_Barr, on Flickr

I can almost certainly find a piston but finding two good barrels in my parts stash is not going to be so easy.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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Re: WBXOily

Postby 300CE » 12 Feb 2018, 21:13

Good stuff Paul - can you put a shout out for the barrels mate? Mines coming out Thursday now as rain stopped play this weekend!!
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Re: WBXOily

Postby itchyfeet » 12 Feb 2018, 21:31

300CE wrote:Good stuff Paul - can you put a shout out for the barrels mate? Mines coming out Thursday now as rain stopped play this weekend!!


looking forward to seeing pics of yours, like this one always good to see the reason for the symptoms.

I will check what I have first, trouble with used is most are scrap or get damaged in the post
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Re: WBXOily

Postby itchyfeet » 13 Feb 2018, 19:57

A good sign that they are all the same weight ( includes one circlip no rings)

ImageP1090542 by Paul_Barr, on Flickr

as are gudgeons, 140-141 is typical

ImageP1090543 by Paul_Barr, on Flickr

went through all my DG pistons to see which sets had odd weights ( quite common when they have been repaired without care) or with damaged pistons.

3 good sets and two odd/damaged sets

ImageP1090546 by Paul_Barr, on Flickr

found two that are 463g and 464g weights, the weight groups are several grams so 3 grams is no problem

Measured up ( more consistent in an old barrel with something to raise it up to the right position to measure)

ImageP1090547 by Paul_Barr, on Flickr

one is a clear winner at 93.94

ImageP1090548 by Paul_Barr, on Flickr

ImageP1090549 by Paul_Barr, on Flickr

measurements are
No1 93.95/?needs barrel
No2 93.93/94.05 = 0.12
No3 93.94/?needs barrel
No4 93.97/94.06 = 0.09
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1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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Re: WBXOily

Postby itchyfeet » 15 Feb 2018, 18:07

I had already honed and sorted the barrels I have to get some for WBXmayo so the best were easy to find, there are two that are OK to repair an engine, just some minor blemishes inside, I think I would be scraping the barrel to find any more to use :D

94.03mm and 94.05mm

ImageP1090551 by Paul_Barr, on Flickr

remeasured the others with the dial bore gauge and measurements were OK before.

so now we have
No1 93.95/94.05 = 0.10
No2 93.93/94.03 = 0.10
No3 93.94/94.05 = 0.11
No4 93.97/94.06 = 0.09

if only I had some rings to fit :D

ImageP1090552 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
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Re: WBXOily

Postby what2do » 15 Feb 2018, 18:48

That ring fairy needs to chop chop so the job doesn't grind to a halt.....
Why would the glass be anything other than half full?

'89 panel van, 1.9 DG.
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Re: WBXOily

Postby itchyfeet » 15 Feb 2018, 19:16

what2do wrote:That ring fairy needs to chop chop so the job doesn't grind to a halt.....


Yes but fitting the rings is a 30 minute job then the gasket kit fairy needs to pull her finger out......
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Re: WBXOily

Postby itchyfeet » 15 Feb 2018, 19:24

Rocker covers are crusty too
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Re: WBXOily rings

Postby oilrag » 15 Feb 2018, 19:31

i have some .....see ad in 4 sale
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Re: WBXOily

Postby itchyfeet » 31 Mar 2018, 17:14

the shopping has arrived....finally :roll:

ImageP1090966 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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Re: WBXOily

Postby what2do » 01 Apr 2018, 16:32

I bet it would look real pretty with some Scat rocker covers......
Why would the glass be anything other than half full?

'89 panel van, 1.9 DG.
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Re: WBXOily

Postby itchyfeet » 27 Apr 2018, 16:13

what2do wrote:I bet it would look real pretty with some Scat rocker covers......


Like a set of shiny alloys on a rusty van?
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Re: WBXOily

Postby itchyfeet » 27 Apr 2018, 16:28

Rainy day perfect for moving this project on.

new crank oil seal

ImageP1100127 by Paul_Barr, on Flickr

cleaned lower oring sealing surfaces and studs

ImageP1100130 by Paul_Barr, on Flickr

replaced the 1D helicoil with a cut down one

ImageP1100132 by Paul_Barr, on Flickr

hello?
ImageP1100133 by Paul_Barr, on Flickr

cleaned piston ring grooves

ImageP1100135 by Paul_Barr, on Flickr

burrs off with reamer so pins slide more easily

ImageP1100211 by Paul_Barr, on Flickr

rings on, these barrels are laid out as they will be fitted so that rings are the right way up and easy to see so they are in the order 2 1 flywheel 3 4

ImageP1100213 by Paul_Barr, on Flickr

into barrels, I prefer front entry not rear entry :lol:

ImageP1100214 by Paul_Barr, on Flickr

new lower barrel seals

ImageP1100218 by Paul_Barr, on Flickr

ImageP1100220 by Paul_Barr, on Flickr

always check clips rotate with one eye pushed toward the other, if not they are not seated.

ImageP1100227 by Paul_Barr, on Flickr

ImageP1100228 by Paul_Barr, on Flickr

other side, tuns over nicely.

ImageP1100229 by Paul_Barr, on Flickr

head nuts cleanaed with a tap, sealing surface cleaned on wet and dry and then all cleaned in a bath of meths

ImageP1100230 by Paul_Barr, on Flickr

why did I touch it...

ImageP1100231 by Paul_Barr, on Flickr

drilled and fixed with a helicoil

ImageP1100233 by Paul_Barr, on Flickr

heads cleaned up ready to fit also, one rust stud left :roll:

ImageP1100234 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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Re: WBXOily

Postby itchyfeet » 28 Apr 2018, 16:36

dry moly on studs

ImageP1100235 by Paul_Barr, on Flickr

green o rings on

ImageP1100236 by Paul_Barr, on Flickr

everything degreased with meths, head sealing surfaces and head nut sealing surfaces

sealant both sides of water jacket seal

ImageP1100239 by Paul_Barr, on Flickr

ImageP1100240 by Paul_Barr, on Flickr

compression seals in

ImageP1100241 by Paul_Barr, on Flickr

yellow sealant on nuts

ImageP1100243 by Paul_Barr, on Flickr

torqued to 50 in 10Nm stages

ImageP1100244 by Paul_Barr, on Flickr

scat big mouth push rods tubes in, pushrods in and rocker gear on, you can use a torch to see the pushrods are seated in tappets
I have NOT reset the adjustments.

ImageP1100247 by Paul_Barr, on Flickr

Last job is the flywheel

Speedi sleeve needed but they need cutting down to about 8mm, I use a dremel cutting disc

ImageP1100250 by Paul_Barr, on Flickr

notch it but don't go too close to the score, I did that on the last one and it split :roll:

ImageP1100252 by Paul_Barr, on Flickr

I use Dirko HT to seal it then bang it on with the tool and peel off the rim

ImageP1100256 by Paul_Barr, on Flickr

tiny bit proud in one place so filed it flush

ImageP1100257 by Paul_Barr, on Flickr

ImageP1100258 by Paul_Barr, on Flickr

all the shims in and the oil thrower and bang the seal in fully underflush so the seal sits central on the 8mm spedi sleeve ( I measured it)

ImageP1100261 by Paul_Barr, on Flickr

ImageP1100263 by Paul_Barr, on Flickr

these can leak so added a smear of Dirko HT

ImageP1100264 by Paul_Barr, on Flickr

110Nm

ImageP1100265 by Paul_Barr, on Flickr

Another WBX saved :D

ImageP1100266 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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