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Ray Vallero stroker build for my '63 ragtop bug
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dsimas62
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PostPosted: Mon Oct 03, 2011 11:57 am    Post subject: Reply with quote

CRUD. Ray's employee had some personal issues come up and has quit and he's all alone at the shop today. Shocked He's been planning on hiring someone, but now he's under the gun and shorthanded. I am putting up an ad for him, but he said for me to throw it on this thread also, just in case.

He needs someone with a minimum of 10 years experience of working on foreign and domestic vehicles as a profession, no smog required. They must be well versed in engine repair as well as service work. Call him directly at 530-823-6193. Leave a message as he may or may not be answering because he's alone there today. You can also email him at [email protected]
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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ralf
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PostPosted: Tue Oct 04, 2011 3:08 am    Post subject: Reply with quote

ahhhh! makes sense

the pistons are short/light in height so the crown may have been thinner than the usual mahle's u can end mill a tub..

i knew ray knew if he can or cannot compromise it!



was worth a suggestion though hehe Cool
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Arnolds64
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PostPosted: Wed Oct 05, 2011 10:30 am    Post subject: W 130 Reply with quote

I am running a W130 Engle on the street with 9.9.1 C/R without issues on my 78x90.5, 2017. 44mm Webers. 043 Heads are ported by me and have 40x 35 valves. It has 108 Overlap as well. Duration at .050 is how 9 degree longer. I would not worry with that cam running 9.5.1. Should work. I had to take out like 10CC on my heads and is a lot for a 8.5.1 C/R with a 110. With the bigger cam had the head flycut .060 an put me at like 50CC.

I am very happy with the way it runs. Plenty of torque for in traffic runs pretty cool unless I am running over 75 for long periods. It just sings to about 6500+ with power. This engine will be strong and very drivable. Stroker cranks really help make them very linear with power in all ranges.

Make sure to buy the large tube Hi perf heater J boxes with a good merged header in combo so it will not run hot. Check this out for your heater -
Works well - http://www.thesamba.com/vw/forum/viewtopic.php?t=443028
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64 Bug, White, 2017, Dual Weber 44's, Engle 130/Engle lifters, Home P&P'd 40X35 heads, CB 4340 nitrided crank, Eagle knock off H Beam 5.5" rods, Lowering Beam, Rancho Trans, Traction Bar. 225X60's rear, 145's front on Porsche Chrome Nipple Wheels.
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dsimas62
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PostPosted: Sat Oct 08, 2011 12:02 pm    Post subject: Reply with quote

Thanks for the input Arnold! Ray said he'd like to go into more detail just on camshafts specifically some time. I think after this build, we will write up some "articles" on some topics and that will be one of them. In a nutshell, the reason Ray prefers cam shafts that are designed to run ratioed rockers is that they have a smoother profile and are easier on the lifter bores. But more on that later.

We are just getting ready to leave for Fontana for Bugorama with Tony and the Zerstorer. But last night, Ray got the heads flycut. Smile

Centering the mill over the cylinder head.

Image may have been reduced in size. Click image to view fullscreen.

First he cuts the head to 94's, then he cuts the top for clearance of the barrel.


Link


Then he checks for clearance between the top of the cylinder fin and the first fin on the head.


Link


Before (in the back) and after (in front). It was only a minmum cut to take the step out and cut the size to 94. It's preliminary since we don't know the cc's of the head yet and there's still a mega shroud right now.

Image may have been reduced in size. Click image to view fullscreen.

We are going to run zero deck with .040 copper shims, which are needed to acheive .040 between the head of the piston and the squench area. We don't want the explosion to take place in the cylinder, but in the combustion chamber. Many people space the base of the cylinders to achieve their targeted compression, but by doing so they have a lazier mix light. Their barrels are blue on the top from the heat of the explosion taking place in the barrel. We will achieve the compression ratio by grinding the combustion chamber. All the heat and power is pushed into the head and into the piston for a more complete burn.

The copper gaskets serve two purposes:

1) As the engine RPM increases, the rod stretches and the head of the piston grows up to .035 at 7000rpm. So if you have less than .040 overall deck clearance, the piston will strike the squench area.

2) There is an iron barrel against an aluminum head and they are two very dissimilar metals in their expansion when hot. Copper absorbs the abrasion caused by the expansion. The shim follows the head back and forth and prevents the head from being worn from skating in and out against the cylinder.

Next we will install the valve seats in order to cc the heads. Then cc them to acheive the 9.68:1, and that will determine how much he will unshroud the combustion chamber around the valves. That will be next week when we get back. Off to the races now, wish us luck!
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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bus guy
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PostPosted: Sun Oct 09, 2011 3:20 am    Post subject: Reply with quote

Great attention to detail and passing on a LOT of years of experience/knowledge. Do you have any pics of Hugo anywhere you can upload?
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bill may
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PostPosted: Sun Oct 09, 2011 9:10 am    Post subject: Reply with quote

you are very fortunate to have him build you an engine. also luckey to have him teach you stuff that helps you understand exactly why and what he is doing during the build.
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dsimas62
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PostPosted: Tue Oct 11, 2011 10:06 am    Post subject: Reply with quote

Bill May: Thank you, I know how lucky I am. I want to document as much as possible from this incredible opportunity. Smile BTW: It is probably no coincidence that your avatar Godfather puppeteer is the same hand that was on Ray's racecar?

Bus Guy: Hugo's in my avatar, but here's some pics. The car hasn't changed much in 30 years. I did the "California Look" stuff in the late 70's when that style was new. Took the chrome off, lowered with a Select-A-Drop (no narrowed beam), 135's in front and 165's in back, removed the beading from the fender seams in front and back for a cleaner look, moved the front turn signals to the vent holes below and used bus back up lights. The interior was out of Steve Browers (Brower's Auto Body in Sacto in the 80's) show car that he turned into a race car back then.

Here you can see the reason for the name Hugo, the old plate was 456UGO.

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Bugorama VIII in Sacto:

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At Donner Summit in 1980:

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Lineup with Auburn Hot VW's, our club in 1983 or so:

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Me in the car (still the same steering wheel) in 1978:

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Me a few months ago at Sacramento Raceway after my tech check in:

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The interior now, same that Steve sold me in 1982 or so:

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The car recently:

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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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RockCrusher
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PostPosted: Tue Oct 11, 2011 10:28 am    Post subject: Reply with quote

Hey Dawn, Hugo is a beautiful little car....and you only add to the appearance. Cool . Keep up the good work!

RC
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I will be happy to speak to anyone who has a serious inquiry (meaning real potential business for RC enterprises) or a parts order. Due to machining noise causing missed calls all calls will be returned promptly.
610-800-0569 (voice mail is Total Home Media.....soon to be changed)
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ralf
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PostPosted: Tue Oct 11, 2011 11:24 am    Post subject: Reply with quote

RockCrusher wrote:
...and you only add to the appearance. Cool . Keep up the good work!

RC



thats smooth right there

Laughing


but seriously.. Hugo got some history! wow.. and years later.. still dashing!


good job , and keep him for as long as u can... Smile
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bill may
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PostPosted: Tue Oct 11, 2011 11:37 am    Post subject: Reply with quote

very nice Beetle. i always used mountney wheels on my beetle as i sold both EMPI gtv wheels i used to use on my beetles.
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bus guy
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PostPosted: Tue Oct 11, 2011 12:18 pm    Post subject: Reply with quote

Very nice! I could see the avatar pics, but wanted to see some better ones. It's great to see a car with the same owner for so long and a true survivor from the early California Look era too.
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padex
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PostPosted: Tue Oct 11, 2011 1:26 pm    Post subject: Reply with quote

That photo from the side profile that old ratty 55 oval window diamond in the rough i bought that car from procter, my mother drove that car to work for six months to a year wile her car was getting fixed. any time i drove it i got pulled over, when she drove it the chp would drive by and give her the thumbs up!
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dsimas62
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PostPosted: Wed Oct 12, 2011 11:03 am    Post subject: Reply with quote

RockCrusher wrote:
Hey Dawn, Hugo is a beautiful little car....and you only add to the appearance.
RC


Thanks RC! Some day there'll be pics of Hugo and I and I'll be old and grey, but the car will STILL look the same. My Immortal.

Padex: Do you still know Jim? I saw him last year. Nice to run into him.

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WE WON AT FONTANA BUGORAMA! Congrats to Tony and Ray for a job well done. He still holds the national record in his class and will win the point series if he simply shows up at the starting line at Phoenix Bugorama next month. Very Happy

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So, back to Hugo's heads. Ray's custom valve guides (shown in previous post) are in place on the exhaust side and will be modified in place. They are much longer and will be ground within the head when Ray ports the exhaust port. The intake guides cannot be in place during porting and unshrouding the heads because it would damage them. Here's the head in the Valve And Seat Machine.

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Ray will now be machining the bowl and unshrouding by hand with a ball mill cutter. But we already showed that when we did it to Lynda's old racebus heads, so no need to repost him doing that here.

The intake valve guide is mounted here on a valve guide pilot to be tapered. It took a while to find the right sized pilot.

Image may have been reduced in size. Click image to view fullscreen.


Link


There is now a 2 degree taper on the guide. The reason for doing this is air flow. This part of the guide sits inside the intake port, and there will now be less material blocking air flow, along with the shape being important. Two degrees results in a long slender taper for optimum air flow.

Image may have been reduced in size. Click image to view fullscreen.
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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dsimas62
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PostPosted: Mon Oct 17, 2011 12:19 pm    Post subject: Reply with quote

Now that Ray has been porting the intake runners, he's discovered he can go bigger than he originally thought. We are now going with 43 x 35. Smile This will allow us to lower the compression to 9-9.25:1. The benefit being it will run cooler. But we won't lose power because it will have a longer torque band of approximately 3500-7000rpms. With larger valves and intake runners the effective ratio actually rises at higher rpms due to complete filling of the combustion chamber. The higher you rev it, the more compression it will get because it will fill the chamber with a bigger load of fuel/air mix. He explained this to me as pouring liquid from a quart jar into a gallon jar and it will splash around more also, for a better burn. Since we are running shorter manifolds, we want to pick up the air speed in the intake manifold right below the carbeurator. This makes the air pull harder to the carb so that there is less hesitation.

Seat pockets with new seats installed, but not ground yet.

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Intake ported.

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This shows the ported intake done on one side, not done on the other yet, for comparison.


Link


Intakes compared between Lynda's old racebus heads (the ones I was going to use) and the new ones (larger now).

Image may have been reduced in size. Click image to view fullscreen.
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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dsimas62
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PostPosted: Mon Oct 17, 2011 12:28 pm    Post subject: Reply with quote

Just an FYI for those interested, here's a video I made of Fontana Bugorama a week ago with Ray and Tony Klink. I had the privilege of being the official tow vehicle driver and provider of food, Monsters, and Rock Stars. Sorry for the shaky camera, I filmed it all with my cell phone, except the in-car camera of the final pass.


Link

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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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wompninja
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PostPosted: Tue Oct 18, 2011 3:06 pm    Post subject: Reply with quote

That's a quick bug.
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ralf
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PostPosted: Wed Oct 19, 2011 6:55 am    Post subject: Reply with quote

just wanna say.. that tony guy... cut a "bad" tree! on that one pass...

right on the blink!
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aircooled356
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PostPosted: Wed Oct 19, 2011 8:08 pm    Post subject: Reply with quote

Thank you for capturing this moment in time. There are very few VW people like Ray Vallero around and to share with the community his machining operations and his dedication to quality work; priceless. Congrats on the season. Thanks again dsimas62
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PostPosted: Sat Oct 22, 2011 5:47 pm    Post subject: Reply with quote

dsimas62 wrote:

Craigman - Yes, Ultra Grey is a silicone hybrid, but not a true silicone I believe. Ray says that they are using a similar sealer at most manufacturers now. Blue Glue was a popular silicone, but wasn't compatible with gas. Loctite came out with a compound that Porsche used, but found later it would separate also. UG has the qualities of silicone, but also has the ability to become more firm upon setup which makes it more difficult to penetrate.

When used on a case, it is pinched so tight to such a thin layer, it squeezes out the extra and leaves an ultra thin skin that is more dense with a stronger gluing ability. It is only a sealer, not to actually glue things together.

i don't like anything that even sounds like silicone. the product you want for sealing case halves is curil t. it is the defacto standard in the air cooled porsche 911 world:

http://vwparts.aircooled.net/Curil-T-Engine-Sealant-75ml-Tube-p/curil-t.htm
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dsimas62
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PostPosted: Tue Nov 01, 2011 2:05 pm    Post subject: Reply with quote

Torsionbar: Curil T looks very similar. Ray's been using Ultra Grey since it came out, 7-8 years and never had a leak. It acts as a seal on a case because it's pressed so thin, that it can then be taken apart. But for barrels it sets up real solid.

Ray's been machining and porting the heads and manifolds and that is a huge undertaking and so not a lot to report on the thread here lately.

BUT, Velvet the bus lost 3rd gear for good, in addition to having trouble now with 1st and 4th, so she's parked. I got a complete bus tranny with RGB's off CL and it needs to be rebuilt, so that is after the motor build for Hugo. That means she'll be sitting for a while, so I said, heck, let's put Hugo's old motor BACK into Hugo so that I can at least go back to driving my car that has been gutted for 3 months.

Image may have been reduced in size. Click image to view fullscreen.

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So, that's what we did this weekend. We invested a bit of time getting the external oil coolers (we decided to go with 2-72 pass instead of one 96 pass) and filters (from the 912 racecar) mounted in the car, since this has to be done anyway.

But, I was eyeballing that competition merged exhaust that is going on the new motor. Who needs heaters, right? Let's stick it on and get a feel for it.

Image may have been reduced in size. Click image to view fullscreen.

And, while were at it, let's put on a little racing pulley that I have for a bit more HP. So, Hugo has some more power in that 28 year old 1600cc, so it's a little kick in the pants to feed the need for speed as I wait impatiently... It is so small that we had to sink the belt down into the generator by putting about 15 shims in.

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These are the braided lines that you want to use with an external filter and/or cooler. I think it is technically an air compressor hose. It is has a stainless steel outer jacket and teflon inner. Burst pressure is 1750#, it's pricey at $11.49 a foot, but so is a new motor. Rubber deteriotes from the day you put it on. This stuff never will.

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Here are the dual oil filters from the old 912 racecar. Oil goes at half speed because the oil is going through both at the same time, not from one to the other. This results in better filtering and less drag on the oil systom.

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Here's a shot from the back, looking at the oil cooler mounted. It is in the center of the picture, under the car, to the right of the shock. We are going to add another one on the right side too, but don't need it for this motor.

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And some shots of the lines. This was time consuming, but the location for the cooler is the best one with lots of air flow, and the lines are tucked up out of risk of snagging. As for where the lines go in and out of the motor: We blocked off the outlet to the oil pump that would normally go to the crankcase and blocked the case inlet off too (see the beginning of this thread). Now the oil can only go out the pump cover (that replaces the stock plate). The line should go to the filter first, so that the oil is hot, when it's thin. Then it goes to the external cooler and back to the case through the main oil galley.

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Notice the hole in the fender well. It was hacked in there when the engine was built 28 years ago. Ray says his kids must have done it, not up to his standard...heh, heh. It's there to be able to access the dual 40 webers. It had covers, but we removed them entirely because Ray is going to enlarge this hole and make a better "door" for them for the 48's.

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Cutting new doors with the plasma cutter (cool tool).

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For the sake of time, it's late and I want to drive my car, we just put them over the old holes. Later when the new motor is done, the holes will be enlarged and cleaned up.

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And from the inside looking at the "doors" on the right and the left.

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It's dark and late. I'll roadtest this week after we rejet the carbs and add the muffler (needs flange mod). And then Ray has to get back to the new motor. Next up on that is shortening the barrels.
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Velvet - '66 21-window walk-through samba bus (Deluxe Microbus with sunroof)
http://www.thesamba.com/vw/forum/viewtopic.php?t=483454

30 year old engine - originally built and being rebuilt by Vallero's VW Werks
http://www.thesamba.com/vw/forum/viewtopic.php?t=571652
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