Saga Engine Rebuild 1971 Bus

[Danwvw]

Its now March 2013 and its been 6 months since I set the end-play and put the CB performance large opening racing push rod tubes on to accommodate the 1.25 Ratio Rockers. Bus has a little over 2000 miles on it since doing this engine work. It's been on a 900 mile trip up the Oregon Coast and back. There is not any noticeable end-play at the engine pulley when I check it now!
Oil leaks are minimal some from the Main Seal which I should have changed but did not as it still was soft. It is leaking just a little not bad at all. I think it is due to the end-play adjustment moved the flywheel further out so the seal is now riding on a new and smaller dia. place on the flywheel seal radius or perhaps the end-play problem it had before opened up the Main Seal a little and it's not sealing well now. There is a little oil coming down the #1,#2 side of the engine case not bad. I tried to be careful when I had the heads off not to brake the cylinder to case seals but I did brake #1 where I just added some gasket seal and put it back together it must be what is leaking. Will Post Photos below!
It should be noted that the engine has not been cleaned before these photos this is 2000 miles and 6 months of accumulation.
#1,#2 Side:

#3,#4 Side:

Looking out the Bay window on the Coast Road to Astoria Oregon:

Bus mascot Meanie watches over driver and passengers on the way to Astoria Oregon.

OverLooking:

The Bridge over the Columbia river:

Return trip Camping:

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Volks Wagen]

Good stuff DanWVW!!! Looks like a nice trip. Get out there and enjoy it, and I hope the bus kkeps going for you.
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1973 1303 with AB-motor - sporadic
reconstruction as time permits, 1986 ex-Bundeswehr Doka - on the road again.

I'm definitely, probably, the worlds greatest lover.

Aithníonn ciaróg ciaróg eile.

[SGKent]

I question whether those are real or photoshopped photos. How come there in no oil drops under that engine - huh? Really drive it you say - eh? Come on, tell us the truth, we can take it.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[airschooled]

[Danwvw]

Thanks for checking the Engine pictures out, Actually I did not know about the Road Draft Boot's. I will need to get one. The bus does not get driven enough these days. But with the previous engine it was driven to work everyday for several years and we made several cross country trips. Thinking about a trip from Oregon to Colorado but want to get the spare motor together first.
Yup. No oil leaks to speak of, not adding oil between changes. Cross my fingers and knock on wood.
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Danwvw]

Up Date: the 1641cc is coming out for new bearings and end-play repairs. Still was running fine though. My U-Tube Video: http://youtu.be/hW9j5YiEplo
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Danwvw]

The end play had gotten worse over the last year. The case is egg shaped at the flywheel main bearing while the others look OK, lifters look good, Need to take some measurements to see if the case can be saved.

My notes say that this case has been already thrust cut to 2nd over and has been aligned bored to to .060" on the mains. Anyone know if there is such a thing as a 3rd over thrust bearing so I can save the case?

Main Bearing Numbers.
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Danwvw]

After taking the 1641 apart I discovered the case main thrust was less than 2nd, 20mm so I found another case. It's a bug case though but I am thinking I can run an adaptor on it when I need it for my 1971 VW Sundial camper Bus.
The case seems to be in good condition and the thrust is standard and the Main Bearing Bore is 1st over.
The 1641 Engine was running fine when I took it out and not using any oil. It only had 25000 miles on it. The 87mm pistons and cylinders should be good still as well as the (35.5 32) valve heads which have 1.25 Ratio Rockers on them and solid rocker shafts and swivel feet adjusters, The stock cam and lifters are in good condition. The Crank although running fine feels a little worn. I have a used 74 mm counterweighted crank a friend sold me and am thinking I should build another 74 mm stroke engine.
What should I build? Just put it back together with the 1641 or build another 1800cc type 1, with 88 mm piston and cylinders. But if I use the old cylinders, would that be a bad idea to re run them with more stroke? Perhaps it would work if I put in Total Seal Rings! But all the decisions aside but this one now. As the subject says: What should I build out of my old 1641 Engine? It would be nice to have it for a ready to go spare engine for either a bug or a bus.
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[busdaddy]

[Danwvw]

They have been in the 1641 for 11 years and have 25000 miles on them. Still can see some hone pattern through the shine of the cylinders. Have to check to see if I can feel a ridge again but I don't think there is one. I have run old pistons and cylinders in the past on other engines but they did burn a little oil when I did that! Thanks for the Reply!
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[SGKent]

[Danwvw]

Trying to decide just what to do with this engine! Took another look at the cylinders and pistons. There is a little tiny bit of a ridge in the cylinders. Looks like the 87mm pistons are AA brand. The thing is they look kind of heavy just like the AA 88mm I just put in the bus's 1800cc type 1! I am wondering if a lighter piston would not be nice for this next motor. Are the Cofap or Mahle or Wesco lighter?
Mahle 85.5mm Pistons
AA Brand 87mm Pistons
88mm Pistons
Wiseco Pistons 94mm
Looks like the Wiseco are only available in the 94mm size!
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Danwvw]

I found an other good used case the only thing is, it's not a Bus Case. It's Likely a California Beetle Case 1971 or 2 with 10 mm studs. So I am wondering it can be modified in some way to use in the bus. I know about the VW Engine Case rear mount adaptor kits but they would seem to rule out the full flow oil pump cover, So I am wondering if there is a way to modify a full flow pump cover to extend out for the needed missing rear mount hole?

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[SGKent]

Dan - re choosing worn and parts that must be modified to fit - you must really like taking these things apart again and see it as a challenge.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[glutamodo]

You really do not want to try to mess with mixing type 1 with type 4 engine setup. Stay with type 4 engine blocks.

[Danwvw]

Well, It is a 1971 (Type 1 Engine Bus) and the Engine Case I am thinking of re-building is also a type 1 Engine. Not sure what VW was thinking when they made these cases with only two of the three needed mount places!

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[telford dorr]

They probably saved a nickel on each case by leaving off the rear mount lugs...

I'd not mess with the bug case. Trade it on a good bus case, and save yourself the grief of a mickey-mouse rear mount.
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'71 panel, now with FI
'Experience' is the ability to recognize a mistake when you're making it again - Franklin P. Jones
In theory, theory works in practice; in practice, it doesn't - William T. Harbaugh
When you're dead, you don't know you're dead. The pain is only felt by others.
Same thing happens when you're stupid. - Philippe Geluck
More VW electrical at http://telforddorr.com/ (available 9am to 9pm PST)

[glutamodo]

[Danwvw]

Well it has taken me several months but I believe I have come up with a case to re-build the original engine from my 1971 Bus with. It has the rear Mount holes etc. I think it may be a Type 3 case, the SN starts with a "U" and is stamped on top rather than the Gen/Alt Stand Base. The Thrust is 1st cut and the the case has been previously align bored 1st over I think? But it is a little hammered out I am hoping it will clean-up at 2nd over on the align bore and not need the thrust cut again.

Probably just build another type 1 1800cc as also found a used 74mm crank!
Will need to source Rods, Cam & Lifters and Heads (The Original Heads are GO-1's with slight cracking. Have a used W-100 cam I could run. Not sure what that would involve, Probably having it turned and new lifters?
Type 3 Universal case to rebuild Original Engine from 1971 Bus with:

SN Stamped on top of Case:

Original Engine from my 1971 Bus.

GO-1 Heads with about 26000 miles on them, have some cracking starting.

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[Danwvw]

Thinking it would be nice to not have to clearance the piston skirts like I had to on the type 1 1800.
Does anyone know if the 90.5mm Pistons will clear my 74mm crank when I use the short 5.325" Rods?
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!