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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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rogertj
Samba Member
Joined: October 07, 2008
Posts: 505
Location: Tijuana, Baja California. Mexico
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 Posted: Wed Mar 22, 2023 2:47 pm Post subject: Re: ABA Vanagon Conversion |
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Looking good!
Tip: When the machine shop does your head be sure to put new guides and valves so that it can last forever. Just went true that issue and is not nice... I mean you are already doing the overhaul you might want to go all new with the head and if there's some change left go for the 270 cam from Techtonics Tunning (TT 8V Hydraulic Lifter Camshaft (266° [AKA 270°] - Street) https://techtonicstuning.com/main/index.php?main_p...64c3bfeb98
Thats the cam that I just placed in my engine and it's a whole different experience
You're going to enjoy the power with new rings!
_________________
Roger
Had a Carbureted ABA after engoing the heck out of it now going for ABA 2.0 Jetta EFI ill put a garrett in to the tin can later or maybe go electric?
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Tue Mar 28, 2023 11:38 am Post subject: Re: ABA Vanagon Conversion |
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| rogertj wrote: |
Looking good!
Tip: When the machine shop does your head be sure to put new guides and valves so that it can last forever. Just went true that issue and is not nice... I mean you are already doing the overhaul you might want to go all new with the head and if there's some change left go for the 270 cam from Techtonics Tunning (TT 8V Hydraulic Lifter Camshaft (266° [AKA 270°] - Street) https://techtonicstuning.com/main/index.php?main_p...64c3bfeb98
Thats the cam that I just placed in my engine and it's a whole different experience
You're going to enjoy the power with new rings! |
I actually planned on running that cam! Can't wait to feel how much better it is with it!
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Mon Apr 03, 2023 6:51 pm Post subject: Re: ABA Vanagon Conversion |
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Did a little more work to the engine today. Honed the cylinders, resurfaced the deck just to get some light surface rust off, and then started to work on the oil pump. I got the diesel vanagon oil pump, and noticed that it wasn't spinning. With further investigation, we found out that there was a flaw with the cast and it was letting metal shards out in the pump. So I'm not sure how much I can trust the diesel pick up tube on the aba pump. So instead of using a diesel pickup tube in the motor, we're going to use the diesel tube on the aba pump to make a jig and fabricate our own pick up tube. More pictures of this will come soon.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Thu Apr 06, 2023 3:59 pm Post subject: Re: ABA Vanagon Conversion |
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Completed the custom ABA pump. Now I'm going to order a brand new oil pump from USRT and put my custom oil tube on the brand new pump/gears. Here is a picture of the diesel pump installed.
And here's a picture of the custom pump installed.
Here is the diesel pump from a view inside the oil pan.
Here is the custom pump from inside the oil pan.
Here is the engine roughly tilted to 50 degrees with the pump installed.
And lastly, here are the two pumps side by side
With some fabrication, it looks like i was able to make my own 50 degree pick up tube. It looks like it will work great!
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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AndyBees
Samba Member
Joined: January 31, 2008
Posts: 2329
Location: Southeast Kentucky
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| Posted: Sat Apr 08, 2023 10:06 am Post subject: Re: ABA Vanagon Conversion |
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When modifying the oil pick-up tube in my ALH TDI for the 50 degree angle, I slightly misaligned it.. It is off by about 5 degrees. I installed it anyway, over 12 years ago and over 85k miles later ....... no problems~!
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003. |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Thu Apr 13, 2023 5:34 am Post subject: Re: ABA Vanagon Conversion |
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| AndyBees wrote: |
| When modifying the oil pick-up tube in my ALH TDI for the 50 degree angle, I slightly misaligned it.. It is off by about 5 degrees. I installed it anyway, over 12 years ago and over 85k miles later ....... no problems~! |
Awesome! Good to hear there are modified oil pick up tubes being ran out there. I usually only hear about everyone getting the diesel vanagon one and just bolting it onto the ABA pump/gears. I'm sure mine is misaligned too, but luckily it's basically just a straw for the engine to pull oil through 
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Tue Apr 18, 2023 7:49 pm Post subject: Re: ABA Vanagon Conversion |
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Got the engine cleaned up enough to bring into the house for measurements. Learned how to use a dial bore guage and measured my cylinder bores. They're all within .001" of where the mk3 bible says they're supposed to be. Pretty much perfect. Might hone the cylinders a little more since I have the tolerance to allow me. Next is to set the piston ring eng gap and then measure the rods and crank caps.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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rogertj
Samba Member
Joined: October 07, 2008
Posts: 505
Location: Tijuana, Baja California. Mexico
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| Posted: Fri Apr 21, 2023 4:45 am Post subject: Re: ABA Vanagon Conversion |
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Looking good!
_________________
Roger
Had a Carbureted ABA after engoing the heck out of it now going for ABA 2.0 Jetta EFI ill put a garrett in to the tin can later or maybe go electric?
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Sat Apr 22, 2023 9:30 am Post subject: Re: ABA Vanagon Conversion |
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Woke up early this Saturday morning to get some crankshaft journal measurements. The main journals all measured 0.0015" smaller than what the Bentley said, and the rod journals all measured 0.0014" smaller. The Bentley also noted that the measurements should read smaller due to oil clearances. So as soon as I check the block main bore and rod big end bores, I'll know if my crank is good or if I'll need different bearings to achieve the proper oil clearances.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Mon Apr 24, 2023 9:41 pm Post subject: Re: ABA Vanagon Conversion |
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Got to checking my main bearing oil clearances. Main bearings 1 - 4 all have an oil clearance of .0025", which is great! When putting on cap number 5, I noticed that I was missing a main bearing cap bolt. Which led me to find out the main and rod bolts are all one time use, so I have a lot of hardware coming in the mail. The build is on pause till I get my new hardware.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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rogertj
Samba Member
Joined: October 07, 2008
Posts: 505
Location: Tijuana, Baja California. Mexico
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| Posted: Tue Apr 25, 2023 9:47 am Post subject: Re: ABA Vanagon Conversion |
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| vw62kid wrote: |
| I also found out that my new main bearing set came with 6 oil grooved shells and 4 non-grooved shells. With some research I learned that main bearing number 4 is the one that gets the 360 degree oil groove. Not too sure on the reason why, I've heard many. All believable too. |
Ups I hope mine doesnt blow up soon! lol!
Im in the middle of a brake after much engine work myself it just crazy...
My best wishes for this build my friend is better to be 100% sure like you are doing it
Keep up the good work!
_________________
Roger
Had a Carbureted ABA after engoing the heck out of it now going for ABA 2.0 Jetta EFI ill put a garrett in to the tin can later or maybe go electric?
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Mon May 01, 2023 5:32 pm Post subject: Re: ABA Vanagon Conversion |
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| rogertj wrote: |
Ups I hope mine doesnt blow up soon! lol!
Im in the middle of a brake after much engine work myself it just crazy...
My best wishes for this build my friend is better to be 100% sure like you are doing it
Keep up the good work! |
I edited this comment, I realized I read your comment wrong.
Factory it had 5 grooved shells and 5 smooth shells so if you don't have the 360 degree oil groove on main bearing #4 I don't see it being an issue 
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111
Last edited by vw62kid on Wed May 10, 2023 5:53 pm; edited 2 times in total |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Wed May 10, 2023 5:50 pm Post subject: Re: ABA Vanagon Conversion |
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Checked all my rod bearing oil clearances. They're all sitting exactly at 0.0014"! Which is right in the middle of the books tolerances! Also installed new rod bolts on them. Next is to bring the block back in the garage, hone the cylinders because there is still visible scoring on the cylinder walls.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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OlisGarage
Samba Member
Joined: June 01, 2022
Posts: 134
Location: Indianapolis, IN
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| Posted: Wed May 10, 2023 9:46 pm Post subject: Re: ABA Vanagon Conversion |
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Great work man. Glad the engine stuff is starting to come together!! It will be worth it long term when you know with certainty that your engine is in tip-top shape.
Keep up the work, and I can't wait to see some before/after shots of the hone!
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1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run) |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Tue May 16, 2023 5:16 am Post subject: Re: ABA Vanagon Conversion |
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Started honing cylinder number 1 last night. Discovered some corrosion on the cylinder wall, so I alternated between honing and measuring to get the corrosion gone without getting out of the .003" wear limit for the cylinder bores. I pushed it almost .002" in the spots with the largest taper/out of round. Generally, these particular cylinder bores .001"-.0015" larger than standard. The corrosion is still slightly there, and I noticed I'm .001" out of round and taper. I'm going to measure again to confirm my measurements are correct. Is .001" too much out of round and taper? If so, would anyone happen to know how it can be fixed?
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111
Last edited by vw62kid on Tue May 16, 2023 10:49 am; edited 1 time in total |
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