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Sat Apr 07, 2007 8:18 pm

Hello, name's wolff, and this is my log of my 2.0L type 4 build up which also will be a cali conversion, for those who dont know what a cali conversion is, basically it is a upright T1 cooling system modified to be used on a pancake engine.

first of all im currently enrolled in the Sacramento Wyotech technical school, so this build may take some time as funds develop, so keep an eye out for updates. also you will notice that im doing most of the work in my apartment, next to my bed to be exact :lol: i do have a little patio for cleaning, painting, and dirty work.

The engine:

as i bought it from a local Pick-n-Pull for $140, not a bad deal in my book,
it came from a '78 bus that was worn out. this engine appears to be rebuilt some time ago as it has been painted.

it is a 2.0L GE model, an early hydraulic lifter equiped model, i will have none of that junk! solid cam and lifters will replace the stockers

So what will this future beast be pushing?
my baby, a '72 ghia:

Ok now to business, a bit of cleaning at the car wash yeiled some good results:

to help fund this build, i already sold the flywheel which was of no use to me, i will need a 200mm conversion flywheel. this as well as most of my parts will come from the king of TIV, Jake Raby.

now to rip this baby apart!

Sat Apr 07, 2007 8:38 pm

first step, see what surprises are under the valve covers:

Hmmm, not bad, looks like this engine may have been cared for. 8)

hows the combustion chamber? looks abit rich but these head will be redone properly,notice those tiny valves? i will have none of those either!
40mm intake, and 36mm exhuast will be on this bill

lovely, still has the dished low compression pistons will a 13mm valley, 914 flat top will take their place, i want some real compression.

Lets dig deeper:

The cam wasnt nearly as bad as i thought it would be, o well, to the trash anyways

case will have full flow drilled and tapped in before getting a good jet wash at the trannsmission shop

there, all apart and ready for some inspection:

can anybody make sence of this rear cam bearing?:

Sat Apr 07, 2007 8:52 pm

now the crank, i will reuse this with the rods after balancing and cryo treatment

comparing a T4 to a T1:

in case you noticed, yes that t1 crank is now a fully functioning lamp
I can make you one!

i also cleaned the case some more:

cylinders look ok, i will clean them a bit more and then hone them

Sun Apr 08, 2007 5:56 am

Kool Keep us posted!

Sun Apr 08, 2007 8:15 am

LOL Rebuilding it in your apartment. Looks fun!

My friend and I(back in our bachelor days) rebuilt stuff in our second floor apartment.

Mon Apr 09, 2007 3:41 pm

So i now just about have my plan layed out and Mr. Raby approves of it so far, i will only trust his advise on this stuff.

i recently cleaned up then heads and i didnt get too far before finding a big ol crack in number 2.

i knew i needed new heads anyways

well now to good news, i got my 2L Porsche 914 flat top pistons:

914 on left, bus on right:

not bad for $75 8)

Sat Apr 14, 2007 5:20 am

ok now to start buiding the upright bit.

take one pair of stock T4 upper tins and cut down the middle as shown:

this pic show a bit more clearly

and repeat with the right side tins
now line them up equally you can see the familiar T1 tin shape appear

some more timming:
the seam only needs to be nice and clean on the outer edges to be welded, the middle bit will be cut out for the fanshroud to throw air in

now some lower/side tins, nothing wrong with the bolt on stock stuff:

and while i still have to cut up another set of upper tins to make the left side,heres a quick mock up of a late model doghouse type 1 shround on the engine.

Thu Apr 19, 2007 3:47 am

ok a few new things, i sold my old set of rockers and bought some 1.7L rockers which according to Mr. Raby, are the best and strongest rockers out there, good enough for me! :)

$42.50 later:

1 hr & 3 scotchbrite pads later:

not quite as nice as Jake's micro polishing:

How does he do it!?

now i may get those rockers and shafts Cryo'd but i see how my budget is doing then, speaking of which, i just sold my '72 bug (which has taken nearly 10 months!) for $2850, not all of that will go in this engine however but it will surely help fund the rest of it. to help im selling the original 2.0 low compression slugs after cleaning off all the carbon:

Porsche 914 left, 2.0 bus right:

Sun Apr 22, 2007 8:01 am

Nice job, so far. You are a brave soul, I would love to see it when you are done. I would love to build a T IV Bug someday, just not enough money anytime soon.
You are right about Raby, from what I hear. Roachghia70 also has a T IV in his Ghia. Using the analogy of Raby being the King, that would make Thomas the qu....Um, Dark Prince from another Kingdom. :lol:

Wed Apr 25, 2007 2:55 pm

nice job. looking forward to seeing the end result. I just picked up a type4 motor from a local swap. good pics as well, im sure i'll use this thread as one of my references.

Thu Apr 26, 2007 6:24 am

Quote: How does he do it!?

Probably in a vibratory type polisher. Harbor Freight sells one for roughly $20 that will polish small objects like bolts and nuts. I think the hopper is 4"diameter and about 4" long. Put the object in it with some abrasive media and it rolls around for a few hours polishing the objects.

Fri Apr 27, 2007 3:33 am

it uses no compounds?

Fri Apr 27, 2007 3:38 am

not one of these right?

Tue May 08, 2007 3:16 am

well ive been shopping for a great deal on some good heads, well i got a break when a guy called me and had a rebuilt set of 2L bus heads that have what i believe are 1.8 valves, anyways it was rebuilt by Rimco so the should be done right. those should arrive this week

in the mean time ive kept on cleaning:

also disasembled the crank for cyro treatment:

i found a use for the rocker springs (which will be replaced by solid spacers) as valve geometry set up springs, this is the old head BTW

and finally i started to grind down the lower face of the rockers .060" for clearancing the swivel feet adjusters which have a thicker foot,only 6 more rockers to go:

Mon May 14, 2007 3:13 pm

I got heads!! yea! and here they are:

old left, new right and rear

they have the 2.0 porsche valves 42X36 so they should flow very well for my application

i will probably replace these springs which look stock to some stiffer ones along with chromoly retainers from the Type 4 store, just for some more insurance

still havent cleaned off the packing fluff :D

stock '78 bus valves on top of these porsche valves, the old exhuast is barely larger than the new intake, silly emission junk :evil:

and again a blurry pic of old on right and new on left

Tue May 15, 2007 1:56 am

I thought I had replied to this thread already? :?

A clean cali conversion is a wonderful thing, and yours seems to be going that way! Let me know if you need any miscelaneous hardware or random parts, because I have a bunch of Type4 stuff that I'm going to be getting rid of soon.

Good luck with your build, looks nice!

BTW, who did you buy those heads from? They look awfully familiar...

Tue May 15, 2007 4:00 am

RoachGhia wrote:

BTW, who did you buy those heads from? They look awfully familiar...

A man named Dale replied to my ad that he had some Rimco rebulit ones, great guy Dale.

more stuff arrived today:

i recieved my new swivel foot adjusters for the rockers, however i have a bit of an interference with the valve covers with them. about 2-3mm.

new rockers, meet new heads:

its hard getting a decent picture of the rocker with a valve cover on the head, but you can see the problem:

also i picked up a valve spring removal tool which i will need to install the geometry checking springs, and its a fun tool :) even if it is overpriced, if i was back home with my welder i could have made one from scratch for 1/2 the price,

so i tried it on my mock up heads, while removing the #3 intake from my old junk heads i noticed a familiar problem to the T4:

so this is why it was junked :?

the seat just fell out in my hand:

notice the height difference between the dropped seat and a moderatley healthy one in #4:

Mon May 21, 2007 2:24 am

got some more tins and a coolinbg fan to help mock the cooling system up.

little closer :D

Sat May 26, 2007 3:02 am

i went to another local pick n pull to help my roomate get parts for his project rx7 and i stumbled across another 2.0 type 4 already pulled and complete.
so i took the tins and a bug gen as you saw above, now at my school another friend has started a crazy project, putting a 200+hp type 4 in the back of his '79 datsun 210 wagon.
i dont know why either, anyways i picked up the engine for him, besides being incredibly dirty (probably from never being rebuilt)

it was in great shape, better than mine actually, even had OG cylinders. it was a vanagon engine and i already put all this work in mine so ill just hold on to it till he picks it up. the heads were junk too, this is a pic after we took it to school to disasemble and cleaned it fora few hours. not a bad deal for $120 either:
the turbo is just a teaser, that is from my mates rx7 turbo build

Sun Jun 10, 2007 11:02 am

bought a little oxy acetylene torch to weld together the tins:

now to cut for the shroud when i get it in the right spot.

also can anyone decifer these main bearings? I need to kno w the size, .10 over?