TheSamba.com :: View topic - 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T.

Sun Sep 03, 2023 10:06 pm

Follow along as I put together a complete 1953 typ 528 Super 1500cc 2pc. case engine build for John T's Coupe. This engine will be built from scratch.
All bits & pieces gathered into one pile and carefully cleaned, fitted & massaged to bring this engine back to life...... Enjoy! 8)

Mon Sep 11, 2023 12:38 pm

Very impressive crankcase, Mr. O. The gold appears to be even more intense than that which you usually use for VW cases. Do you keep the case in the Alodine soaking longer than for VWs? Did you bore the cylinder openings for a larger diameter than the original 80 mm?

Mon Sep 11, 2023 1:10 pm

Rome wrote: Very impressive crankcase, Mr. O. The gold appears to be even more intense than that which you usually use for VW cases. Do you keep the case in the Alodine soaking longer than for VWs? Did you bore the cylinder openings for a larger diameter than the original 80 mm?

To answer your questions in order:

What I've noticed on the earlier blocks, the "gold" is more intense than the post 1956 blocks. Also, 2 blocks usually don't come out looking the same.
I'm thinking that the alloys when melted were not consistent so each block had different "hues" when treated after they came out of their molds.

Alodine is NOT used for magnesium but rather aluminum. I'm very familiar with Alodine because I used it on aluminum surface skins on the C-17
US military cargo lifter while employed at The Boeing Company. The Alodine that I used for aluminum does nothing to the surface nor appearance
on magnesium. I do not do the chem. treatment. I send my blocks out to be done by a professional that has been in the business for over 40 years.
My understanding is the chemicals are very toxic and causes cancer if not properly handled.

I use Dura-Bar cylinders and like to "clean-up" the bore openings. The P/C's are 80mm

Mon Sep 18, 2023 3:03 am

Watching this thread. This should be interesting.

Mon Sep 18, 2023 10:24 am

Fresh 10/10 crankshaft assembly that has been balanced along with conn. rods ready to assemble.

Mon Sep 18, 2023 11:49 pm

Ready to close 'er up.........

Tue Oct 10, 2023 9:08 am

More photos..........

Tue Oct 10, 2023 10:06 am

That's pure mechanical art. Following and can't wait to see the finished engine.

Sun Oct 15, 2023 10:34 pm

Heads and valve train are on.........

Tue Oct 17, 2023 7:08 am

Hey Joe, Interesting valve springs...looks like a flat inner spring (or damper?). What is the source of these and do they work well? Thanks

Tue Oct 17, 2023 9:01 am

alanhall wrote: Hey Joe, Interesting valve springs...looks like a flat inner spring (or damper?). What is the source of these and do they work well? Thanks

These springs have a flat inner damper / spring, not the usual rolled wire. I got them years ago from an old Pre A guy. They work well as they don't have
the extreme lifter pressure that the modern 356 valve springs have for the later mushroom lifters. Never had any issues. My engines seem to love 'em.

Wed Oct 02, 2024 8:27 pm

Repairing heater box flappers......

This was the old, holey & rusted piece that I removed. You can see the "donor".

Piece spot welded.......

As fitted and installed......

Sun Oct 13, 2024 9:52 pm

Front breast plate was previous repaired by a "metal guy" and when I secured one side, the other side was W A Y off!
This piece of tin is the most visible and needs to fit nothing less than perfect!

So I took it apart......

And re-fitted the pieces...........

Tue Nov 26, 2024 9:46 am

Although the firewall tin is hardly noticeable, it still needs attention. The seal channel strip
is always beat up so this needs to be removed and replaced with "fresh" metal...

Horizontal side pieces get the same treatment.......

Wed Nov 27, 2024 6:55 pm

Welded rear channel strip.....good as new! :wink:

Wed Dec 04, 2024 12:46 pm

Now that I have all 3pcs. of the rear breast plate located in the correct positions, I spot welded them together, I can now focus on installing
the new channel tack strip. Here, I'm measuring the CORRECT length it should be when it meets the side horizontal piece. Note where I
marked with an arrow where the edge of the horizontal pc. ends. This is where the channel strip is suppose to end and NOT where it was
previously located by past "metal guy". :(

Sat Dec 07, 2024 11:23 pm

Spot welded the 3 channel strips to their perspective tins. Notice how there's no mis-alignment where they
meet so the rubber will stay uniform when the engine is installed.

Mon Dec 16, 2024 6:41 pm

Pre-fitting everything before final tack weld together....