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Hugging Corners
Samba Member
Joined: June 17, 2009
Posts: 140
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 Posted: Thu Mar 10, 2011 9:34 am Post subject: |
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i want moore!!
man you made it so easy better than manual that you studied from:)
i see that you used lots of chemicals to clean the motor. Grime is my worst nightmare, i cant stand it.
I have to try simple green, so far have been using mild paint stripper and denatured alcohol minute after to clean the case, dont know if its unhealthy for aluminum case, but instant effect.
for pitted metal oxalic acid (hope name is right- so called wood bleach) bath. Overnight this acid dissolves all the rust, but its so mild it can leave plastic and even stickers intact.
...just wanted add 2 cent, but you are making sweet 1600dp rebuild document!
HxC |
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dawerks
Samba Member
Joined: September 15, 2010
Posts: 2349
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| Posted: Thu Mar 10, 2011 10:00 am Post subject: |
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Excellent! 
Newbie Question; Did the machinist give you the bearings when the work was done? How about the cam bearings?
_________________
"There is only one sin; disconnection from self." |
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torsionbar
Samba Member
Joined: December 11, 2010
Posts: 2215
Location: earf
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| Posted: Thu Mar 10, 2011 10:06 am Post subject: |
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| flyboat wrote: |
| If the job is worth doing, its worth doing right. It looks good |
this x1000. do it right the first time. no point in doing it any other way.
nice work and nice photos! |
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Fri Mar 11, 2011 9:06 am Post subject: |
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| dawerks wrote: |
Newbie Question; Did the machinist give you the bearings when the work was done? How about the cam bearings? |
I just went and bought them from a VW shop called Autosport. They get them from Northwest Connecting Rod in south Seattle. Cam bearings too - but they're standard size, as they usually are. |
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KingAir42
Samba Member
Joined: May 24, 2002
Posts: 500
Location: Bakersfield
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| Posted: Wed Mar 16, 2011 8:57 pm Post subject: |
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great work so far.
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A stitch in time saves nine |
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bladerunner80
Samba Member
Joined: February 13, 2011
Posts: 255
Location: Fife, WA
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| Posted: Mon Mar 21, 2011 11:38 am Post subject: |
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This is awesome! I just picked up a complete 1600 Dual Port off craigslist last week that I'm going to rebuild. I've never rebuilt an engine before, so I picked up the "How To Rebuild Your Volkswagen Engine" book.
I'll be referring to your thread a lot when I start tearing into later this week! |
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cutter8174
Samba Member
Joined: January 11, 2011
Posts: 131
Location: Hatfield, PA
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| Posted: Tue Mar 22, 2011 8:29 am Post subject: |
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| I love this posting its so helpful with my own build for the first time also. |
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Sun Apr 03, 2011 2:16 pm Post subject: |
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| I'm out of town until May, so no updates till then. Sorry everyone. |
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Aynthm
Samba Member
Joined: July 07, 2010
Posts: 1315
Location: Beaverton, Oregon
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| Posted: Tue Dec 13, 2011 2:22 am Post subject: |
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| maboyce wrote: |
| I'm out of town until May, so no updates till then. Sorry everyone. |
I was hoping there would be a conclusion to this post!
May came and went.
Whatever happened to "maboyce" and his engine? |
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JimmyBK
Samba Member
Joined: September 27, 2011
Posts: 44
Location: Brooklyn
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| Posted: Tue Dec 13, 2011 9:46 am Post subject: |
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| Aynthm wrote: |
| maboyce wrote: |
| I'm out of town until May, so no updates till then. Sorry everyone. |
I was hoping there would be a conclusion to this post!
May came and went.
Whatever happened to "maboyce" and his engine? |
My bet is, he got back & finished it, but rather than showing the end on the internet he took it out for a ride and never came back on the internet |
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MrVWGuy
Samba Member
Joined: February 21, 2010
Posts: 643
Location: North of Pittsburgh PA
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| Posted: Tue Dec 13, 2011 10:11 am Post subject: |
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| JimmyBK wrote: |
| Aynthm wrote: |
| maboyce wrote: |
| I'm out of town until May, so no updates till then. Sorry everyone. |
I was hoping there would be a conclusion to this post!
May came and went.
Whatever happened to "maboyce" and his engine? |
My bet is, he got back & finished it, but rather than showing the end on the internet he took it out for a ride and never came back on the internet |
Or possibly some of the gobs of blue RTV that was used found it's way into an oil gallery, plugging it up & causing a bearing or two to spin... 
_________________
'63 Bus (camper of unknown origin)
'62 Beetle
'68 Kombi
'76 Westfalia camper, the wife's |
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Glenn73
Samba Member
Joined: May 30, 2011
Posts: 1190
Location: West Jordan UT
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Tue Dec 13, 2011 1:42 pm Post subject: |
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Sad to say what happened is that the author went back to school, so all of his time and money went away. I did get as far as putting the exhaust on, but then discovered that the decked heads I inherited messed with the geometry enough that I couldn't get it to go on properly. I didn't really want to use those heads anyway (this is not a motor to run at higher-than-stock compression; it was a pretty tired case and crank), but I didn't have money for others and had no time to monkey with bending up the stock muffler to make it fit.
I do have pictures of everything up to that point...maybe I'll try to write up the rest of what I have during vacation. If some altruist wants to trade stock dual port heads for my cut ones, things might proceed again. |
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Aynthm
Samba Member
Joined: July 07, 2010
Posts: 1315
Location: Beaverton, Oregon
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| Posted: Tue Dec 13, 2011 8:53 pm Post subject: |
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| Hey, sorry to hear that. Anyway, you can still finish oneday. |
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beetleman217
Samba Member
Joined: April 03, 2011
Posts: 515
Location: Canada
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| Posted: Wed Feb 15, 2012 6:58 am Post subject: |
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What does Thrust Cut mean? I understand that Align Boring is grinding material from the case where the bearings sit, in order to have an aligned passage for the crank. But thrust cut means what?
Thanks
_________________
If all else fails, stop using all else
1977 Westfalia
1961 Beetle |
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DesertBob
Samba Member
Joined: February 09, 2004
Posts: 1245
Location: Goodlettsville, Tennessee
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| Posted: Wed Feb 15, 2012 8:02 am Post subject: |
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I vote sticky for this thread. Awesome details and thank you for your hard work and effort.
_________________
All it takes is a little imagination, some mechanical ability, and neighbors who mind their own business
74 Super Beetle (German Look Project)
Full Flow 1776 with 36 Dells, 4 wheel drilled and slotted disc brakes, Porsche 7x17 Turbo Twists, Topline Maxx Struts, Camber kit, 7/8" Front Sway bar, Rear Sway bar, Urethane bushings all around. |
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Sat Oct 13, 2012 12:38 pm Post subject: |
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I'm back. I cut up my car and hauled it away, because it had accident damage and I realised it didn't really pay to fix it, but I still have two engines worth of parts. So I'm going to finish this one, and one more, for the experience and to get the stuff out of the garage.
Part of the reason it took me so long to finish this is that I used the wrong sealant on the case halves and a few other places - hardening brown shellac-based stuff that, according to the Samba, gets ground into powder as the case halves expand and contract over and over again. I had the short block put together, but I stripped it back down completely and got out the lacquer thinner.
Not fun. I even removed the pressure-relief valves and all the silicone used there and around the cylinder studs. I had to take the case halves back to the machine shop to go through the wash tank again because little crumbs of sealer got everywhere when I opened the case. |
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Sat Oct 13, 2012 12:47 pm Post subject: |
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Pressure relief valves
The procedure was the same as last time, save that I used a brush to apply sealer - much neater and less dangerous.
I also used new aluminum sealing rings from the gasket set (from two gasket sets, actually; they only come with one).
The valve, spring, and plug were lubricated and installed at the pulley end...
...and at the flywheel end.
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Sat Oct 13, 2012 12:49 pm Post subject: |
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Sealing studs
I re-sealed the cylinder stud holes with blue RTV, with a brush this time.
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maboyce
Samba Member
Joined: December 21, 2009
Posts: 182
Location: Olympia, WA
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| Posted: Sat Oct 13, 2012 12:52 pm Post subject: |
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Main bearing stud sealing rings
New main bearing stud sealing rings were installed dry.
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