Club 80-90 Forums

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" onclick="window.open(this.href);return false;

0.32mm shim
https://www.brickwerks.co.uk/t3-parts/e ... -3542.html" onclick="window.open(this.href);return false;

99289 Speedi sleeve
http://www.ebay.co.uk/itm/99289-SKF-Spe ... 2281057745" onclick="window.open(this.href);return false;

VR Full gasket set
https://www.vwheritage.com/025198009b-g ... t-vw-spare" onclick="window.open(this.href);return false;

x4 DG piston ring sets
https://www.brickwerks.co.uk/t3-parts/e ... dh-cu.html" onclick="window.open(this.href);return false;

8x telescopic push rod tubes ( we binned the originals)
https://www.vwheritage.com/ac1094109a-s ... e-vw-spare" onclick="window.open(this.href);return false;

Cleaned up pistons and barrels tonight

This is common, green oring is unrecognizable

P1090532 by Paul_Barr, on Flickr

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

P1090533 by Paul_Barr, on Flickr


cleaned up with a nylon wheel

P1090536 by Paul_Barr, on Flickr

honed

P1090537 by Paul_Barr, on Flickr

No 3 has had it along with No 3 piston

P1090540 by Paul_Barr, on Flickr

P1090539 by Paul_Barr, on Flickr

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


P1080792 by Paul_Barr, on Flickr

other pistons cleaned up OK

P1090541 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.

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

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

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

P1090542 by Paul_Barr, on Flickr

as are gudgeons, 140-141 is typical

P1090543 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

P1090546 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)

P1090547 by Paul_Barr, on Flickr

one is a clear winner at 93.94

P1090548 by Paul_Barr, on Flickr

P1090549 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

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

94.03mm and 94.05mm

P1090551 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

P1090552 by Paul_Barr, on Flickr

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

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......

Rocker covers are crusty too

i have some .....see ad in 4 sale
oilrag.

the shopping has arrived....finally

P1090966 by Paul_Barr, on Flickr

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

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

Like a set of shiny alloys on a rusty van?

Rainy day perfect for moving this project on.

new crank oil seal

P1100127 by Paul_Barr, on Flickr

cleaned lower oring sealing surfaces and studs

P1100130 by Paul_Barr, on Flickr

replaced the 1D helicoil with a cut down one

P1100132 by Paul_Barr, on Flickr

hello?
P1100133 by Paul_Barr, on Flickr

cleaned piston ring grooves

P1100135 by Paul_Barr, on Flickr

burrs off with reamer so pins slide more easily

P1100211 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

P1100213 by Paul_Barr, on Flickr

into barrels, I prefer front entry not rear entry

P1100214 by Paul_Barr, on Flickr

new lower barrel seals

P1100218 by Paul_Barr, on Flickr

P1100220 by Paul_Barr, on Flickr

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

P1100227 by Paul_Barr, on Flickr

P1100228 by Paul_Barr, on Flickr

other side, tuns over nicely.

P1100229 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

P1100230 by Paul_Barr, on Flickr

why did I touch it...

P1100231 by Paul_Barr, on Flickr

drilled and fixed with a helicoil

P1100233 by Paul_Barr, on Flickr

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

P1100234 by Paul_Barr, on Flickr

dry moly on studs

P1100235 by Paul_Barr, on Flickr

green o rings on

P1100236 by Paul_Barr, on Flickr

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

sealant both sides of water jacket seal

P1100239 by Paul_Barr, on Flickr

P1100240 by Paul_Barr, on Flickr

compression seals in

P1100241 by Paul_Barr, on Flickr

yellow sealant on nuts

P1100243 by Paul_Barr, on Flickr

torqued to 50 in 10Nm stages

P1100244 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.

P1100247 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

P1100250 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

P1100252 by Paul_Barr, on Flickr

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

P1100256 by Paul_Barr, on Flickr

tiny bit proud in one place so filed it flush

P1100257 by Paul_Barr, on Flickr

P1100258 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)

P1100261 by Paul_Barr, on Flickr

P1100263 by Paul_Barr, on Flickr

these can leak so added a smear of Dirko HT

P1100264 by Paul_Barr, on Flickr

110Nm

P1100265 by Paul_Barr, on Flickr

Another WBX saved

P1100266 by Paul_Barr, on Flickr