TheSamba.com :: View topic

Thu Apr 03, 2008 10:47 am

Hello all

I'm planning to build a new engine for my '71 panel.

It would be a week end driver, on a "light" panelvan compared to a westy camper for example, I'd like to have it pulling right 'till 6500RPM like my old 1775 did

Starting with it:

***********************************************************

New AS41 case, full flowed, stroker clearanced

4340 forged 78mm crank

DRD 5,4" I beam rods

Stock weight 8 dowelled flywheel

AA 92 thick walled pistons & liners, Bugpack retainers

My Steve Tims Stage 1 head which were on my 1775 (40*35,5 heads, dual valves springs, P&P, 163 cfm @ 0,6" on a French flow bench -> flow charts here), chamber's volume setted to 53cc

CR 9:1 with my 58cc heads and 1,2mm ( ~ 0.05 " ) deck-height.

DRD 1,4/1 rockers

A1 1"5/8 SS Sidewinder

Twin 40 DRLA's with 34 mm chokes

**************************************************************

Week-end driver only ( ~ 3000 miles a year)

I'm hesiting between two cams

Engle FK42 or FK43 both with 1,4 ratio rockers

Was planning to use an FK42 but I'm afraid it is a little too nice for this setup?

Which would be the best for my setup? want to have my engine pulls like a rocket lol!

In fact I'd like to have the same conduct like my old 1775 but with a 2l engine torque :P

I hope to read you soon!

Thanks viNce from France

Thu Apr 03, 2008 12:39 pm

Im running a FK-42 in my baja in my 2017 with 9.5:1 and it pulls pretty hard. I was having carb probs with it, and havn't taken it out of of winter storage and swapped my new carbs onto it yet, but I'm sure there is a potential for more. Not sure how it wil be in a bus application, but I would think you'd be ok.

Thu Apr 03, 2008 1:26 pm

Bashr52 wrote: Im running a FK-42 in my baja in my 2017 with 9.5:1 and it pulls pretty hard. I was having carb probs with it, and havn't taken it out of of winter storage and swapped my new carbs onto it yet, but I'm sure there is a potential for more. Not sure how it wil be in a bus application, but I would think you'd be ok.

hi, whats your valve size? no overheating and pinging?

Thu Aug 14, 2008 5:11 pm

Hello all 8)

Some little news about my bus,

Got all my parts,

New Chromoly Head Stud kit

Scat Lube A Lobe SLR'ed lifters

New custom built Engle dual lobe FK43 intake / FK7 exhaust machined on a Scat SC1 blank to have a perfect cam/lifters adequation, this blank is also factory clearanced for the rods

New DRD 1,4:1 ratio rockers with Bugpack schims and lash caps

New 92's TW pistons & liners kit

New AS41 case

I also received new ignition parts

Pertronix muti curves distributor

Pertronix 8 mm low resistance wires

Flame thrower II coil

All my engine parts are now collected, but the engine is in stand by because I'm waiting for a total seal second rings set and a missing scat chromoly long head stud, only 15 studs in the package :x

Here is the work that has been done :wink:

The case, back from cylinders boring

Some accessories

Matched oil pump/case galleys (done in house :wink: )

All case plugs drilled and tapered

Machining for the crank and rods + breathing

Matched pistons weights

"Race" german oil pickup

Checking rings gaps

Checking endplay

Checking deck height

Case decked to the exact value

Fitting all tins before going for powdercoating

Going up to 57cc (50 béfore) on the heads to reach 9:1 CR

Working man 8)

and done

Replacing the 8 pass cooler from this

To this

Now I'm waiting for the missing parts to assemble the engine, all is checked and rechecked (clearances, plays ...)... Just have to clean and install the parts définitely like à LEGO 8)

In parallel, I welded a late bus gearbox brace, it needs a lot of modifications but well worth it to avoid any case crack like I had on my 1775 engine (case broken on the 3 rear moustache bar mounting boss, now running in a friend beettle) :shock:

Cleaned

Sand blasted

Primered

Got a late bay "clutch house" (How do you call it in english??)

Cut cut cut

Check

Weld 8)

Cut

Flying gearbox :wink:

Primer

Draw

Cut

Weld 8)

"shave"

And finally paint !!!

That's "all" folks :lol:

More pics on my blog (in French sorry)

Fri Aug 15, 2008 1:00 am

Thanks for sharing all the photos, what speed is your bus doing in the gears at 6500?

Fri Aug 15, 2008 1:23 am

Hello thanks for your interest :wink:

It's about 40 Km/H in first, 70 in second, 115 in third, never gone @ 6500RPM in fourth gear :wink:

You can look at the inside video above , the speedo is ~ 10 Km/h excessive due to my 195/50/15 front tires, (we can see my speedo @ 80 km/h in second gear with my old 1775 engine at about 4'50" when I reach the highway, memorise the sound, you're @ 6500 :D )

Fri Aug 15, 2008 6:09 am

Hello,
I have a question about your motor.
How much lift at the valve will you have with your cam and the 1.4 rockers?
With 1.2mm deck high and your cam/rocker combo, will you have have to notch the pistons?
Regards

Fri Aug 15, 2008 7:20 am

Very nice build. The mount conversion looks like it was OEM!! The split cam combo sounds interesting.'m using the FK 7 in my 2180's rebuild instead of the VZ 25 style cam I had. The VZ 25 pulled real hard considering it was only being fed by a single 32NDIX Zenith. I will soon know how hard the FK 7 pulls.

Thu Oct 09, 2008 10:12 am

jubibug: I have 13.6 mm IN and 12.7 mm EX theorical lift @ the valve, I checked valve to piston Clearance and it's ok --> 2,5 mm between the intake valve & piston, sorry to talk with european units :wink:

Here is the second batch of pics as I forgotten to update this topic :roll:

Case machined to have the exact Deck Height:

Checking the new DH, with 1.2mm on all 4 barrels

Installing chromoly studs on the case for the rear hanger, more resistant than the stock system.

Finishing the fuel & breather lines:

Finishing the manifolds match porting,I bought my manifolds bare not reworked by Steve & Greg Tims

Setting the Rockers end play 0,1 mm on all.

Last view of the Steve Tims heads (home made reworked chambers to achieve 58cc as they came with 53 cc for my old 1775 and 50cc after the flycutt to accept the new 92 Thick Walled cylinders) & manifolds:

New Berg retainers to have more spring clearance:

Berg magnet:

Last "moke up" of the long block

intake Retainer to Guide clearance (1,5mm)

Full lift:

Valve to piston clearance at th most "critical" point, At this point I can move the valve (witch is without spring) on 2.5mm before touching the piston.

Thu Oct 09, 2008 10:49 am

Here are the last pics of my build, concerning the final assembly of the short block:

Installing the rods on the crank, streching is checked on each bolt after being torqued

Case closing:

ARP lube on the case bolts:

Installing the sump and others accesoiries:

Flywheel torked to 45M.KG

More accesoiries to cover all the holes...

Cutting to lenght the head studs

Installed:

Final assembly of the pistons & cylinder with TS second rings, cleaning:

Setting rings gap:

Assembly:

New springs:

Near to be ready to run with a Steve Tims head / 40 DRLA on the left and GB865 / 48 IDA on the right :lol: :lol: no that was just for the pic:

With its future owner on the background:

Back on the track,

Reworked keepers (they are not touching when installed)

Checking for coil bind:

Now the engine is just waiting me to coming back from Paris to reinstall the valves on the heads and the heads on the short block for the first start, the new exhaust is also nearly to be finished by A1 & shipped to France 8)

Bye!

Vince

Thu Oct 09, 2008 5:10 pm

That's clean work! thanks for the updates and clear photos! Wear goggles when you are grinding your heads! Plese keep us informed of your progress and when the engine is running!

Roland from NY

Mon Nov 03, 2008 5:17 am

Hello all, I left you with my short block done, now the engine is done, just waiting for it's new exhaust which should arrive later this week...

I'll start it for the cam breaking in for the Xmas pupils vacations beacause I have to go back in two days in Paris for work untill this date... and I think I will not have received my exhaust yet... :cry:

So I left you with my coil bind settings... I had to make another 3 angles intakes valves job because I was too short before coil bind, so I sent my heads to a good machine shop, because the lack of material does not allow to cut the intake spring bases without going into the intake port.

Here is the old "stone" valve job:

And the new one done on a CNC seats cutter 8)

Valves are 2.5mm down to achieve 3mm before coil bind conbined with the Berg GB281A retainers and GB 273A dual springs.

On the exhaust side, I used the Berg springs cutter because there is enough meat...

I reshaped my chanmbers around the "new" valves seats

done:

New valves job

After that, I did the valve train geometry, using soft Type 4 rocker shafts springs...

Because they were on my old 1775, my push rods were shortened on a lathe, -5mm for the intakes, -4mm for the exhausts ones.

Had to cut my valves covers to clear the rockers

And after that I installed the berg springs, and definitely installed my heads, with some Hylomar under the washers and RTV159 silicon between case & cylinders.

Some glossy paint on the tinware 8) 8)

And the engine is now done, just waiting its pushrods tubes when it will be on my bus (to hard to install when the engine is not tightened on something) and it's new sidewinder exhaust! Some news in December now... :cry:

More détails on my blog!

Mon Nov 03, 2008 8:39 am

Just saw the whole thing, very nice. Thanks for all the pics. I drooled on the keyboard and didn't even realize it until I got to the end. You weild the dremel with the skill of a Jedi.