Stop smoking...

Big lumps of metals and spanners. Including servicing and fluids.

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sarran1955
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Stop smoking...

Post by sarran1955 »

and breath deeper....

Hello,

Here is a bit of air cooled fun... :wink:

Various people have commented on my CT van engine being a heavy smoker...about 40 unfiltered a day... :roll:

This little engine was built up from scrap, and has been whizzing round Europe for 10 years..

However, on returning from Bergerac, there is a 30 km climb on the motorway, which is always a good test of the engine, where I lost power
and sprayed oil all over the engine compartment from the dipstick tube..

Serious crank case overpressure.. :shock: :shock:

I have been looking at an engine upgrade for a while, something that will improve uphill performance on the motorway.

Typically, something like this:

Image

However, at 830€ plus postage, for a standard 1584 cc motor, I thought I would look elsewhere..

So here is the offer from AA performance parts in California.

1 x Black Front Tin: 71 & Up DogHouse for $16.95 each
1 x VW 1600 Dual Port Performance Cylinder Heads, 40X35.5 "Pair" for $479.95 each
Bore Size:92 Bore (Add $20.00)
Springs:Single High Rev
1 x VW 88 x 69mm 1700cc Machine-in Piston & Cylinder Kit for $176.95 each


Discounts : $-101.07 USD

Subtotal : $572.78 USD

Shipping : $171.88 USD

Total : $744.66 USD

Even adding 68€ import duty, this seems good value.

The 'big bore' machine in kit has the same dimensions as the 1700 cc cylinders used on a Mexican/Brazilian engine produced for a sports car in the mid '70's.
This means it has a standard wall thickness, thus avoiding the warping problems sometimes encountered in the 1641 conversion.

The bigger (stainless) valves will help breathing, maybe with a new carburettor set up.

So the order was placed on line... a tip to save money, is to open the account, 'like on FB'..gives a 15% discount, then place the items in your basket. Log out and wait till the next day. You then receive an e mail from AA saying that your order is saved, go back to the basket and a DHL delivery option is shown,(as opposed to US mail.)
This is cheaper..and I got my parts in 5 days.

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Cordialement,

:ok
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937carrera
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Re: Stop smoking...

Post by 937carrera »

sarran1955 wrote:
The 'big bore' machine in kit has the same dimensions as the 1700 cc cylinders used on a Mexican/Brazilian engine produced for a sports car in the mid '70's.
This means it has a standard wall thickness, thus avoiding the warping problems sometimes encountered in the 1641 conversion.

The bigger (stainless) valves will help breathing, maybe with a new carburettor set up.

I think the new piston rings will help with the breathing most of all. :D

I'm interested in what engine/ car the 1700cc engine you refer to was from. It's actually 1679cc, which made me think they were the same as the type 4 411/412 engine, same cc, but the capacity is reached through 88 x 69 rather than 90 x 66. The most likely car I thought of was the VW Brasilia, but that was a 85.5 x 69 engine, type 1 derived and same as the CT.

You're actually going to have 1835cc, but with the same cam. I expect that the larger valves will allow higher revs, what sort of power are you expecting, around the same as a CU ?
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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itchyfeet
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Re: Stop smoking...

Post by itchyfeet »

Whats that that UK plug socket doing on the wall of your workshop :shock:
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

itchyfeet wrote:Whats that that UK plug socket doing on the wall of your workshop :shock:

Despite being French, I have always preferred the UK 3 pin outlet system... :wink:

My granite house on a granite mountain has been struck by lightning several times, and so all circuits are earthed, via a 'parafoudre', the phone line has an anti lightning 'cartouche' on the outside of the building.

The secondary circuits are all UK standard.

So all my plugs have fuses, and there is no risk of polarity inversion (with Euro 2 pin plugs).

But lightning is strange stuff...after the last strike, the dishwasher started leaking...the drain hose clip arced to the chassis of the machine... :roll:

I rent my Livebox from Orange, for 1€ per month, on condition that I unplug when away, or when they sent an 'alerte' by SMS

We have many 'micro-coupures' where the electricity cuts off for just long enough to set all electronic clocks to zero... :x

However the EDF have greatly improved the local grid 'reseau' and in a couple of years the suspended cables in front of my house,power and phone, will be buried.

Great lightning yesterday, with sunshine on the left, and a hailstorm sweeping in from the right... 8)

Sending you a pm Itchy...

Cordialement,

:ok

Oh.. and yes I do have a UK type outlet in my van.. :rofl :rofl
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itchyfeet
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Re: Stop smoking...

Post by itchyfeet »

sarran1955 wrote:
So all my plugs have fuses, and there is no risk of polarity inversion (with Euro 2 pin plugs).


Yes indeed, I got a shock a couple of weeks ago in Portugal, was tinkering inside an open product that was switched off but not unplugged, the switch was one pole and switching neutral, plug in upside down.

I won't make that mistake again.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

Believe in coincidence........ :roll:

In my letter box this morning is a leaflet explaining that there will be a survey of the village, for installation of fibre optic in 2019..

So my ugly lamppost might be gone.... 8)

Cordialement,

:ok
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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Flikr test

Can every body see at the back.. :?:

Image

Thanks Paul
Image

Ralf85
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Re: Stop smoking...

Post by Ralf85 »

sarran1955 wrote:Flikr test
Can every body see at the back.. :?:
Image
Thanks Paul
Get on with it John. It's time for a new YouTube engine rebuild video. I've seen all your other ones! :)

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

Seem to have the Flikr mastered for now.....

So as so many threads lost their photos, I thought I would recap for any newer members...

I'm getting too old to struggle, so here is my easy engine out...

The CT in all it's glory with the lifting chains in place:

]Image

The jack and engine hoist are in place, note the smooth rolling, clean plastic work surface:

]Image



The jack is to make removing the engine carrier 'surprise free',

Then as the engine is lowered to horizontal, the gearbox axle stand goes in place:

]Image

Now the top bolts can be loosened easily, especially the starter motor 'D' bolt

]Image

So now the hydraulic engine hoist loads the motor into the trailer, and so up to the workshop:

]Image[

Then drive into the workshop and lift the engine onto it's 'servante' with the winch...

]Image[

All of this achieved with 'No Unpleasant Bending'......... :)

Beer break time..

]Image[

Air cooled bliss... 8)

Cordialement,

:ok
Image

Ralf85
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Re: Stop smoking...

Post by Ralf85 »

Your Massey Harris tractor is the star so far. I love it.
:ok

weimarbus
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Re: Stop smoking...

Post by weimarbus »

Ralf85 wrote:Your Massey Harris tractor is the star so far. I love it.
:ok
+1 :ok
1985 hi-top 2.1MV with DG carb and LPG
1955 trials buggy with 1.9 DG high lift cam and twin dell's (now sold)
1972 1303 beetle
1992 Audi 100 2.8 quattro estate
1967 Vw  Madison kit

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

Ralf85 wrote:Your Massey Harris tractor is the star so far. I love it.
:ok

Henri le Pony (1953) is just the thing for cruising the streets of downtown Sarran...a red mono-seater with 24 inch rims... 8)

6 volt, starts on the 4th turn of the engine.

So, onto stripping down the old cylinders and heads..

Image

Rather handy with Beetle cylinders on CT heads, as I can stop THAT stud from turning..

I'm leaving the oil filter, cooler and flywheel on, so that when I tip the motor on end, I can see if there are any oil leaks..


Image

and yes the oil cooler is suspect..

and when the cylinders are withdrawn..

Image

A veritable puddle of piston rings... :shock: :shock: :shock:

So, this morning I have been 'pruning' my CT/T2 stock.............why so many cylinders :?:
Nice and tidy...and 2 spare oil coolers.. :)

Now I'm off in my mini- coach to take little old ladies shopping in Town... :)

Cordialement,

:ok

Oh, and yes there will be videos.. :)
Image

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

So the adventure continues.....

]Image

The old scrap goes to be 'weighed in'

Enough pots to make to make a couple of flat 6's. :roll:
]Image

Now for the rest of the strip down..

Engine mount off and oil filler pipe, a VW spanner is very useful..
]Image



Clutch off:

]Image

Fly wheel removal bar tool:

]Image


]Image

Use a 3/4 drive and a 36 mm socket:

]Image

The motor is lowered into the Congo Republic:

]Image

No photo, but a section of angle the same length as the 'cheater bar' is clamped to the Fly wheel removal bar tool

Then a 1/2 inch drive 24 mm socket to slacken the fan mount bolt.

Image

Now with the motor on the 'servante', we remove the fan mount from the crankshaft:
Image

Then the Woodruff key from the crank, gentle persuasion and freeing oil will help:

Image

Image

When you clean up the Woodruff key, it is worth shortening it by 4 mm, with the reduced bit facing into the engine, this is so you
can fit the seals easily, and the one inside the fan bolt mount will not get crushed by the Wfk.

]Image

Now for the fly wheel end, The crankcase oil seal does not leak, but is not OEM,

]Image

replaced by a 'Bruss' with VAG logo and part number..

]Image

Reassembly, finally the clutch is torqued down..

]Image

The torque figure given for the fan mounting to crank in Haynes must be a misprint. 60 dan is quite sufficient.
+++++++++++++++++++++++
Now that all the case seals have been changed, we can start to mount the cylinders..

Air-Cooled Bliss...

Cordialement,

:ok
Image

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

Well, I've made some progress, despite the thunder storms.. :roll:

As I came home in my school coach, I was confronted with this:

Image

Lightning had struck the medium tension line, (the one that goes through my woods), and destroyed the step down transformer..

This taken later shows the state of the circuit.. :(

Image

After a deal of running about, (never use DPD / Chronopost), I picked up this nice package:

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containing a pair of Solex pdsit 35 carburettors.. :) ....Thanks Professor..

Then these two, with spark plugs and gaskets..

Image

Meanwhile, I had left the spare oil coolers under leak test, Filled to brim with thinners and left overnight..

Image

Then the usual degreasing, cleaning, and fettling before paint:

Image

I know there are those among you that do not like Hammerite, but I feel that the 8 year old paint job has held up well,
some of the black will just need a repair here and there

Image

Only on the bottom plates does the paint need removing and re doing:

Image

Silver and black..

Image

So that is the tinware and exhaust prepping, hopefully I can now get on with the build....

Air-cooled Bliss...... 8)

Cordialement,

:ok
Image

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sarran1955
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Re: Stop smoking...

Post by sarran1955 »

Hello,

Now we can look at the new cylinder heads...

I've spent some time doing the video of these heads, so you will have to wait patiently.. :roll:

However, here are some pics...

The question I ask, and hopefully answer is, can you use these heads straight away, with no valve lapping or fettling..

The answer is yes, the only flaws were very minor.. :)

Here is the roughness that I machined away..

Image

Then the paraffin test..53 ccs per chamber, left 1/2 hr.. no leakage..

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Then a 'dry' assembly of the head and manifolds..

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to make sure that the studs are not over length...

Image

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Don't forget to recover the little heat deflector .. :wink:

Image

So far so good..

Pistons and cylinders next.. 8)

Cordialement,

:ok
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