Build Project: Wilbur’s 2.1 DJ

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Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 31 Mar 2020, 15:19

Idle hands and all that! Got a engine to build. The other head will arrive once Will has got the exhaust off it - usual stud shenanigans. This is what we have:
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Last edited by DoubleOSeven on 31 Mar 2020, 19:01, edited 1 time in total.
1984 Caravelle 2.1 MV
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 31 Mar 2020, 18:55

Pretty sure this engine has been stored in a muddy puddle! ;)
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But it’s cleaning up ok.

Got a few boxes of bits:
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Need to get these barrels off:
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 31 Mar 2020, 18:57

Mud on it was covering a crack. Not a major, can be welded. Has not penetrated to coolant part as far as I can see.
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Re: Build Project: Wilbur’s 2.1 DJ

Postby Wilber » 31 Mar 2020, 19:04

Looking good and you’re progressing very well! If to you think the crack is an issue, unfortunately no one is going to be able Tig weld that with the current climate. Have another case if you’re feeling adventurous!


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1983 Westfalia PopTop 2.1 DJ
1986 Sika 2.1 DJ
1989 Doka 4.6 V8
1989 Sika 2.0 ADY

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Re: Build Project: Wilbur’s 2.1 DJ

Postby ajsimmo » 31 Mar 2020, 20:04

Another engine? I thought you had a rebuild in 2017? Did it have problems?

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Build Project: Wilbur’s 2.1 DJ

Postby Wilber » 31 Mar 2020, 20:37

Nope, that 2.1 DJ is running very well indeed and married to an AAP in my pop top campervan. This engine is destined for the next coffee van which was going to debut on 12th April. Date TBC as paint shop is also affected......

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1983 Westfalia PopTop 2.1 DJ
1986 Sika 2.1 DJ
1989 Doka 4.6 V8
1989 Sika 2.0 ADY

1986 T25 Trailer
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Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 01 Apr 2020, 18:39

Tapped the M8 threads on head #1 and started cleaning. Got one barrel off. Other one proving a bit stubborn. I’ll get it in the vice and find a piece of block wood + club hammer. Then blow torch the rings out.
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Any ideas what this bracket is for?
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Changed out the M14 sump plug. It had 2 copper washers on there. Cleaned the thread.
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Found this spark plug in my stash. Emergencies only, you understand! ;)
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 01 Apr 2020, 21:39

This engine really is filthy. I need to clean out the gunk from these cooling veins at the very least. Brake cleaner and a tooth brush I think.
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Re: Build Project: Wilbur’s 2.1 DJ

Postby ajsimmo » 01 Apr 2020, 23:08

DoubleOSeven wrote:Any ideas what this bracket is for?
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Exhaust support plate bolts to it on a late WBX.

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Re: Build Project: Wilbur’s 2.1 DJ

Postby jacobh » 02 Apr 2020, 06:41

Please check the thickness of the oilpumpgasket from the Victor Reinz set. In my set it was way too thick and gave me a headache to find where my low oil pressure came from. In the end I didn't use a gasket only a sealant.

But there are people on this forum who can better inform you about this than me.
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 02 Apr 2020, 16:17

Will do, thanks.

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Crowbar 1 - Barrel 0
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 02 Apr 2020, 18:01

Cleaned up ok

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Checking the valves

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Re: Build Project: Wilbur’s 2.1 DJ

Postby colinthefox » 02 Apr 2020, 20:19

jacobh wrote:Please check the thickness of the oilpumpgasket from the Victor Reinz set. In my set it was way too thick and gave me a headache to find where my low oil pressure came from. In the end I didn't use a gasket only a sealant.

But there are people on this forum who can better inform you about this than me.


That'll be me then. I've been banging on about this for ages! Glad someone's taking notice, if not the suppliers :)
1.9D (AEF) pop-top. Aaaaahhhhh........that's better.
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Re: Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 03 Apr 2020, 09:24

Late head, C suffix

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Build Project: Wilbur’s 2.1 DJ

Postby DoubleOSeven » 03 Apr 2020, 19:11

Reseated the x4 valves in this head.
Before:
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After:
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