Big bore 40 horse clearance issues.

[bonecollector]

A couple weeks a ago I started putting together what was going to be a temp motor for my 61 single cab. Now $700.00 later the entire top end is new including some big bore pistons and cylinders. I was under the impression these mahle 82.95 mm piston and cylinders were a bolt on item but I am running into clearance problems on the #3 hole. It appears that the cradle of the piston needs to have about 1/8 inch of material removed to be able to clear the case. Machining the piston seems to be the easiest answer but it also sounds like a bad idea to me. I will post some links to pics of my project here. Any ideas or help would be greatly appreciated. Jer.

Here is a picture of the area of the case the piston is hitting: http://www.thesamba.com/vw/forum/album_page.php?pic_id=233022

Here is a pic of the stock piston height to the bottom of the cradle:
https://www.thesamba.com/vw/gallery/pix/233025.jpg

Here is a pic of the big bore piston height to the bottom of the cradle:
http://www.thesamba.com/vw/forum/album_page.php?pic_id=233021

Here is a pic of the pistons side by side you can see the obvious difference in the cut out of the cradle:
http://www.thesamba.com/vw/forum/album_page.php?pic_id=233023

Here is a pic of the two pistons next to each other. There is a considerable difference in width which also could be a factor in the clearance issues:
http://www.thesamba.com/vw/forum/album_page.php?pic_id=233024

Any info is greatly appreciated. Jer.
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[bonecollector]

[img]http://www.thesamba.com/vw/forum/album_page.php?pic_id=233024[/img]

[img]http://www.thesamba.com/vw/forum/album_page.php?pic_id=233022[/img]

[img]http://www.thesamba.com/vw/forum/album_page.php?pic_id=233021[/img]

[img]http://www.thesamba.com/vw/forum/album_page.php?pic_id=233025[/img]
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[Envious]

Welcome to the club I've attached a few links with the same problem. The threads don't all start with this topic but end up there eventually.

I just picked my pistons up on Friday from having the skirts milled down. Some guys have clearanced the case instead.

Either way, read these threads. Lots of good information.

http://www.thesamba.com/vw/forum/viewtopic.php?t=134825&highlight=40hp

http://www.thesamba.com/vw/forum/viewtopic.php?t=1...mp;start=0

http://www.thesamba.com/vw/forum/viewtopic.php?t=129792
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http://www.thesamba.com/vw/forum/viewtopic.php?t=388225