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The building of a Type 3 2332
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Notched
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Joined: January 19, 2003
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PostPosted: Tue Feb 13, 2007 11:46 am    Post subject: The building of a Type 3 2332 Reply with quote
I'll have to update the specs of the motor again.

Dan Evison is the engine builder - just so you know who Dan is...

Bolting the case together with the bearings (test fit):

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Case bolted together with bearings:

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Checking bearing specs:

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Rods:

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Crank detail:

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Pics of me cleaning out the motor case, and deburring the edges:

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Detail shot:

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Made some progress on the motor! After tons of problems with two sets of rod bearings, Keller Machine finally found some bearings that worked! I ended up getting some Chevy 2.8l bearings that fit the bill. Last weekend spent a little time at Dan's shop and he started assembly. Had a little scare with one of the rod bearings, but Dan did a little filing, and everything is A-OK!! I am stoked!!!

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One main bearing in place!

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1st rod in place!

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2nd and 3rd rods in place!

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All four getting torqued down.

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Final torque. Man they were all nice and smooth. I gotta give props to Dan, he really takes his time to make sure it's all right. All four rods felt nice and smooth. Looking forward for more progress!!

Some pics of the shortblock progress:

Case tapped for Type 3 full-flow

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Checking the distributor drive shaft for clearance

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Clearanced side of case for distributor drive shaft

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Drive shaft in place

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Installing small crank bearing

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Small crank bearing on

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Checking large crank bearing in case

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Had a lot of problems with the key for the fan. You can see how this crank was machined too far down into the shoulder. The key kept moving to far down:

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Here you can see the key pushing down too far:

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After some creative clearancing on the key, it fit and the oil washer fit (what the hell is that thing called?)

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Installing cam gear (ooooooo, I love the sound of straight cut gears!):

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Installing cam bearings:

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Checking cam play against thrust surface:

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Cam back out, installing lifters:

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Crank installed:

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Crank and cam installed:

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Now you can really see those straight cut gears! Cool

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Closing the case (it will have to get opened up on more time after the cam is dialed in)

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Case closed:

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Check out the recessed washers:

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Case fully bolted down, nuts torqued to 25lbs (remember this is not final):

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Dropping in temp pistons and barrels:

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Don't worry, we're just using these pistons temporarily to dial in the cam

The correct pistons are ordered for the 84mm crank

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Dialing in the cam

Deck height tool used to find TDC:

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If you look at No. 1 intake, Dan had a lifter with a rod welded to it

I think this is No. 1 intake...

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It's tough to tell, but Dan is rotating the crank and watching the guage here:

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Guage at TDC:

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This is a nice closeup of the dial indicator guage and the lifter tool:

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I guess this is the reader's digest big print version (degree wheel):

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One bolt in cam gear getting tightend down after cam is dialed in:

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So, that's where we're at. Short block pretty much done. Just need to pull the case apart and take out the lifter tool, drop in the rest of the lifters and tighten down the cam. Dan also wanted to make sure the cam bolts have enough clearance from the case.

Dan had to order some parts for the long block. He said we could hit it again next weekend. I'll have to bring more peanut-butter shakes...

Engine update. New build sessions.

This is where we left off. Short block was almost done. It sat in hibernation for a bit.

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Balanced flywheel (balanced with whole rotating assembly, crank, rods and pressure plate)

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Final assembly of short block. I didn't have all of the lifters in before. Cam plug wasn't in either. And, had to torque down the cam bolts.

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Final torque of cam bolts

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Cam in. Final assembly of the short block. I wish I would have taken more pics here. The other half of the case received the rest of the lifters. My engine builder had some cool springs to keep the lifters in place. I really wish I had a pic of that. O-rings added to the 6 case studs. Special German sealant added between the case halves. Cam plug in. One thing to note is that Dan likes to start tightening the two cam studs first on the case.

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Test fit of full flow fittings

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I'm using 94mm Mahle "B" pistons for the 5.5" rods

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Adding cylinder studs (I don't know how I ended up with so many of these pics...) Engine builder had a cool tool that fit over the studs, and would allow for tightening without utilizing the threaded areas

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My engine builder likes to set end play while the pistons and barrels are still off. Can't get an accurate measurement with them on.

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The pistons were weighed and came out dead even out of the box!

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Had to check the deck height. This motor is set up with a zero deck.

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Pic of the shims used for the cylinders

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Once the correct number and size of cylinder (barrel) shims were established, we started final assembly pistons and barrels

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Some shots of my DRD Racing Heads – These are DRD Stage 5 heads. 40x35, ported and polished, matching intakes, bench flowed. Some of the pics have two valves out to see inside

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Close up of the intake

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CCing the heads (this may be out of order, I can't remember if we did this earlier)

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Final assembly of the the heads

.060 copper head shims were used.

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This copper shim was inserted into the head. I don't have a good pic of the copper shim in the head unfortunately...

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One side

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Other side

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Voila! Almost a longblock! Just need to set up the valve train geometry.

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Leak down test was between 12 and 18% for all cylinders!

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Some Pics:

Push rods cut. Rockers installed. (I need to post a few more pics that I have here)

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Here you can see the Kymco 1 5/8" exhaust not quite fitting on the 1/2 side. Just a little short.

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Cutting at no. 1 port. Or is it no. 2?

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Test fitting exhaust.

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Welded back together.

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Copper exhaust gaskets.

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Finished exhaust.

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Throttle body with exhaust.

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Test fitting oil pump.

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Pulling back out to see where cam bolts interfere.

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Clearanced oil pump.

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Pump drive gear welded.

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New oil cooler stud.

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Oil cooler and pressure fitting.

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Oil cooler installed.

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Cylinder tin over oil cooler.

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Cylinder tin test fit on 1/2 side.

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Intake manifold gasket. I had to match these to the ports. DRD marked them for me.

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Intake manifold test fit.

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Cylinder tin test fit on 1/2 side with deflector plate.

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Test fitting the distributor.

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Final installation of oil pump and test fitting of full-flow fittings.

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Rear engine carrier test fit.

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Installing muffler. I need to take this back off, but it kept Harrisen busy...

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Setting up the throttle body linkage. Had to clear the distributor.

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Inspecting the fuel injection wiring. This required taking off two miles of electrical tape...

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Starting to hook all of the connectors on.

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Gettin' closer!!

EFI + MSD wiring.

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I need to tap the head for the head temp sensor.

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EFI wiring.

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Control box and switched wire.

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Oil filter mount using Parker -8AN fittings.

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Another pic of the oil filter mount.

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Fan.

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Pulley shroud on.

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In this pic you can see the flange that I've removed from the sheet metal.

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Alternator on with pulley and belt.

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Here you can see the alternator and MSD distributor touching. I need to fix this so that the distributor can rotate.

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Gettin' close!

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Sooooo close!

3/8" fuel line running to the fuel rails on the throttle bodies. The coil is mounted, but I haven't added the connectors to the end of the wires yet. You can also see that I need to tap the head for the temp sender for the EFI.

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This is a pretty good shot of the fuel line. I had to make a few bends to go around the distributor and center pivot for the throttle body linkage. I'm going to add the fuel regulator on the 1/2 side. I've taken off the alternator, until I can fix the clearance issue with the distributor.

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Nice close up of the fuel line. The line is really close to the throttle body. I'm going to fix this with some fittings.

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This is were I landed this weekend.

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And a shot of my work area.

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So close, yet so far away...

Last edited by Notched on Mon Mar 10, 2008 12:21 am; edited 13 times in total
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vwfye
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PostPosted: Tue Feb 13, 2007 12:14 pm    Post subject: Reply with quote
the notch still ain't gonna move! Wink i'm jealous of the FI buddy! real jealous
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Notched
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PostPosted: Wed Feb 28, 2007 12:25 pm    Post subject: Reply with quote
I'm keeping all the updates in the first post. Updated.
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

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Towel Rail
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PostPosted: Thu Mar 01, 2007 12:03 am    Post subject: Reply with quote
Nice pictures! Looks like you've got a good builder too.

BTW, what's with the European time stamping on the pics? Razz
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Notched
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PostPosted: Thu Mar 01, 2007 2:40 am    Post subject: Reply with quote
The motor is for a European car... Laughing

I have no idea actually. The camera that I'm using was set up that way. I've been too lazy to fix it.
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

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Bobnotch
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PostPosted: Thu Mar 01, 2007 3:29 pm    Post subject: Reply with quote
Really nice pics. The engine looks to be going together with a lot of attention to detail. Is this an all aluminum case? Keep up the photo gallery, I mean work. Wink
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Notched
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PostPosted: Mon Mar 12, 2007 10:15 am    Post subject: Reply with quote
Just noticed your question Bob. Yes, it is an early aluminum case. They are a LOT of work. Lots of cleaning the insides. Sand casting a case is not a great idea, IMHO. But, it was free...

My MSD distributor was shipped along with a MSD coil and wires! Whoohoo!
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org
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Notched
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PostPosted: Tue May 01, 2007 10:57 am    Post subject: Reply with quote
I'm adding more pics to the first post...
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org
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COFBack
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PostPosted: Tue May 01, 2007 12:38 pm    Post subject: Reply with quote
Nice Jugs ! !
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Notched
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PostPosted: Thu May 03, 2007 9:57 am    Post subject: Reply with quote
More pics added.
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

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Notched
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PostPosted: Fri Jun 08, 2007 3:29 pm    Post subject: Reply with quote
Hoping to get back to the 2332 next week. My engine builder is going to college, and classes end this week.
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

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Oregon VW Forum -- http://www.oregonvw.org
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Notched
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PostPosted: Mon Nov 26, 2007 12:58 pm    Post subject: Reply with quote
Long story short – finally getting back to this build. I've ordered Scat rocker assemblies from my friend David's shop... [plug]Bug Boys Classic VW in Medford[/plug]

Hopefully they will arrive this week, or next... Then I can get to the valve train geometry. Need to cut some pushrods! Stay tuned...
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org

Last edited by Notched on Mon Nov 26, 2007 2:26 pm; edited 1 time in total
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jaransonT3 Premium Member
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PostPosted: Mon Nov 26, 2007 2:06 pm    Post subject: Reply with quote
Looks like you and I are in about the same place with the builds. I have one of my rocker assembies put together, but didn't have any shims to set the geometry. Plus I need to make a better adjustable push rod. My first attempt failed. <G>
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Notched
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PostPosted: Mon Nov 26, 2007 2:27 pm    Post subject: Reply with quote
From what I now know, that is the key! A good adjustable push rod.

I forgot you are building a big motor too... What is the motor for? Sophy?
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org
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gixxer 711
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PostPosted: Mon Nov 26, 2007 2:32 pm    Post subject: Reply with quote
boy, that is a great builder to let you take pics durin the work. that can such a distraction.
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PostPosted: Mon Nov 26, 2007 5:30 pm    Post subject: Reply with quote
Notched wrote:
From what I now know, that is the key! A good adjustable push rod.

I forgot you are building a big motor too... What is the motor for? Sophy?

Yup. for Sophy.

90.5 x 78.8 (2027cc)
40x35.5 home ported/chambered heads
C35 Scat cam
9.0 to 1 compression
SDS port fuel injection and ignition
Single 51mm throttle body
M45 supercharger Twisted Evil
custom 1.5" exhaust

Should be fun. Just hope I can package it all under the engine cover otherwise the blower won't go on this engine.
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John Jaranson
'66 Square
'69 Square
'70-1 Fasty
https://www.carartbyjohn.com
https://www.carartbyjohn.com/2024Invasion/
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Notched
Samba Member


Joined: January 19, 2003
Posts: 2365
Location: Pacific Northwest
Notched is offline 
PostPosted: Mon Nov 26, 2007 7:03 pm    Post subject: Reply with quote
Nice! I'm using the same exact cam.

I think a larger exhaust system would be good with that blower...

Toby had heat issues with his normally aspirated motor (2110?) with *I think* 1.5" exhaust...
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org
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ntimid8
Samba Member


Joined: September 08, 2007
Posts: 94
Location: Sacramento/Orangevale
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PostPosted: Mon Nov 26, 2007 11:16 pm    Post subject: Reply with quote
Nice pics. How much power are you hoping to make? What does something like this cost?
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Notched
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Joined: January 19, 2003
Posts: 2365
Location: Pacific Northwest
Notched is offline 
PostPosted: Tue Nov 27, 2007 1:01 am    Post subject: Reply with quote
Thanks. I'm hoping around 150hp. This motor is built for torque.

Cost? I'm going to make a detailed list of prices. My first loan was $3000 -- this was built on a budget, I got some good deals on a lot of it. The case was free! That saved about $400.

Those heads were about $700...
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Phillip Bradfield

Current stock: '57 Panel Bus, '63 Rat Notch, '64 Baja, '66 Variant, '67 Convertible Ghia, '68 Squareback, '69 Squareback, '69 Fastback

Southern Oregon VW Club -- http://www.sovw.org

Oregon VW Forum -- http://www.oregonvw.org
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COFBack
Samba Member


Joined: July 05, 2005
Posts: 2148
Location: Colorado Springs
COFBack is offline 
PostPosted: Wed Nov 28, 2007 7:05 am    Post subject: Reply with quote
Did you say what fuel delivery system you are using?

That is a sweet looking engine.
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