PetenAli's WBX 2500 engine build
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weimarbus
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Re: PetenAli's WBX 2500 engine build
That is a thing of beauty
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
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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silverbullet
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Re: PetenAli's WBX 2500 engine build
Hang your head in shameSyncrobaz wrote:Ash tray ?????
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Things have been held up due to a camshaft manufacturing cockup that has now, finally, been resolved.
Hopefully I will be back on this one next week...
Hopefully I will be back on this one next week...
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ozzi_in_the_uk
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Re: PetenAli's WBX 2500 engine build
silverbullet wrote:Things have been held up due to a camshaft manufacturing cockup that has now, finally, been resolved.
Hopefully I will be back on this one next week...
Goody, goody ....I can't wait!
The anticipation I have watching this thread to unfold, is even worse than wating for the next season of 'Game Of Thrones' to air!!
You know nothing, ...John Snow!'
1988 - 2.1i wbx - Microbus SA Import
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davegsm82
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Re: PetenAli's WBX 2500 engine build
silverbullet wrote:Things have been held up due to a camshaft manufacturing cockup...
Sorry for the thread Hijack, who would I need to talk to about having a Camshaft made up for a TDi? Not your usual 'more lift/duration' job, something a little bit different...
Dave.
'87 Devon TDi 'Lily'
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PetenAli
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Re: PetenAli's WBX 2500 engine build
Just back from a couple of weeks in La Belle France. Good to see things moving forward. E mail coming your way tonight Ian with a bit of "project management" stuff in it! 
1987 Westy Syncro 2.5 DJ (Courtesy of 025MOTORSPORT)
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Syncronaut #171
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Ok. I have been pretty busy all round, had to have an epic tidy up in the "engine room" and around the works generally, we were climbing over things...not good!
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Nice and tidy in the engine assembly room again 
Must get rid of the blackboard...
Must get rid of the blackboard...
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lloydy
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Re: PetenAli's WBX 2500 engine build
A blackboard is a awesome thing to have! Gotta keep it!
Time is a drug. Too much of it kills you
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Chalk = dust. Not good for bearings. Whiteboards make far more sense. Just like in hospital wards
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Dremels are toys
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silverbullet
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Re: PetenAli's WBX 2500 engine build
I am amazed at the Oettinger approach to crankcase clearancing, it seems that they went for the "carve plenty out" & "just grind that off" approach by the time they got to my engine (#53)
On this and subsequent 2.5 builds I have elected to go for the more detailed "remove enough, but no more" method.
I have also done a little de-flashing inside and some detail work to remove sharp edges that could all adversely affect windage and oil drain-down. It only takes minutes but its worth it, especially if it prevents a stray bit of casting flash becoming detached...
On this and subsequent 2.5 builds I have elected to go for the more detailed "remove enough, but no more" method.
I have also done a little de-flashing inside and some detail work to remove sharp edges that could all adversely affect windage and oil drain-down. It only takes minutes but its worth it, especially if it prevents a stray bit of casting flash becoming detached...
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Good day on this one. The rotating assembly now comfortably clears when trial fitted in each half (using my 2500 crank, rods and old pistons)
Next step was to make a fixture to hold the rods, so as to machine them each end as per Oettinger (lightening and clearance)
An hours' CNC setting and machining will see them ready to hone and then we can start building!
I have gone right off using ARP Chevy rod bolts for the following reasons: the fit is excessive so they stretch the big end and make it out of round even when reamed to the correct size; the location diameter is in the wrong place so the cap and rod are actually worse located for using them; they are bulkier than the VW ones so make even more clearance problems.
I will stick with new 9mm VAG ones thanks all the same: I am convinced that all con-rod failures are down to lack of a proper oil cooler, not simple mechanical fatigue.
Next step was to make a fixture to hold the rods, so as to machine them each end as per Oettinger (lightening and clearance)
An hours' CNC setting and machining will see them ready to hone and then we can start building!
I have gone right off using ARP Chevy rod bolts for the following reasons: the fit is excessive so they stretch the big end and make it out of round even when reamed to the correct size; the location diameter is in the wrong place so the cap and rod are actually worse located for using them; they are bulkier than the VW ones so make even more clearance problems.
I will stick with new 9mm VAG ones thanks all the same: I am convinced that all con-rod failures are down to lack of a proper oil cooler, not simple mechanical fatigue.
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PetenAli
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Re: PetenAli's WBX 2500 engine build
Well impressed with the detail and care Ian.
1987 Westy Syncro 2.5 DJ (Courtesy of 025MOTORSPORT)
Syncronaut #171
Syncronaut #171
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silverbullet
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Re: PetenAli's WBX 2500 engine build
Thanks. Its all in the details Pete, I take pride in my work and don't want any job coming back to haunt me.