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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 10:45 am Post subject: Re: ABA Vanagon Conversion |
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Found some more information. My maximum allowed taper is .0016", which means I'm good there. My maximum allowed out of round is .001", which means I'm right at tolerance. I'm going to measure again to confirm, and continue to try and get that corrosion pitting out. If it's too far gone, I'll have to rebore the cylinders. If that's the case, I'm going to go as big as possible. I believe that would be +1mm, it would put me at 83.50mm bore. We'll see where this build takes me next.
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59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Wed May 24, 2023 3:34 pm Post subject: Re: ABA Vanagon Conversion |
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Decided to not push tolerances and overbore my cylinders from 82.5mm to 83.5mm. With that being said, some forged high compression 83.5mm bore JE pistons forced their way into my build against my will. Also purchased a set of brand new JE piston rings. Next is to send my block back to a machine shop for overboring.
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59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10379
Location: Sunshine Coast B.C.
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| Posted: Thu May 25, 2023 3:54 pm Post subject: Re: ABA Vanagon Conversion |
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Nice to see the progress.
As a (still) newb to engine rebuilding, looking at your build, I can see there's things I would've done better on my ABA rebuild. Regardless, with about 50K+ km's on it, it's still running fine as a DD.
IOW, your engine will last longer than mine. LOL !
I'm glad I went with new pistons though I stayed at stock bore dimension.
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
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vw62kid
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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: Sat Jul 15, 2023 2:00 pm Post subject: Re: ABA Vanagon Conversion |
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That's great news to hear, I think I'm going to go the same route as you if my cylinders come up with problems after the oil starvation issue I had months ago.
From what I'm reading Vanagon Nut had a really good used engine installed!
your engine vw62kid is definitely going to last for thousands and thousands of miles. I recommend that you get the best oil pump you can get! If you have to buy from Germany go for it! You can even buy 2 just in case! I made the decision to buy from Autozone and it failed after 250 miles!  After I rebuilt the engine so lessons learned to me.
Im going to start rebuilding mine in a couple of days for sure and maybe go for the 3.285 pistons and rebore on cylinders its up to the bore gauge when it gets true the mail because I want to avoid pulling the engine out again. Lets hope for the best and if not just deal with it lol!
Keep up the good work!
PS. Did you buy the 270 cam? EDITED: I didnt pay attention in class I think you did? lol!
Regards
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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?
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Fri Jul 21, 2023 12:40 pm Post subject: Re: ABA Vanagon Conversion |
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| rogertj wrote: |
That's great news to hear, I think I'm going to go the same route as you if my cylinders come up with problems after the oil starvation issue I had months ago.
From what I'm reading Vanagon Nut had a really good used engine installed!
your engine vw62kid is definitely going to last for thousands and thousands of miles. I recommend that you get the best oil pump you can get! If you have to buy from Germany go for it! You can even buy 2 just in case! I made the decision to buy from Autozone and it failed after 250 miles! After I rebuilt the engine so lessons learned to me.
Im going to start rebuilding mine in a couple of days for sure and maybe go for the 3.285 pistons and rebore on cylinders its up to the bore gauge when it gets true the mail because I want to avoid pulling the engine out again. Lets hope for the best and if not just deal with it lol!
Keep up the good work!
PS. Did you buy the 270 cam? EDITED: I didnt pay attention in class I think you did? lol!
Regards |
Oh man that sounds like a nightmare. Yeah, I got the USRT oil pump. A lot of the guys in an ABA performance builders page on facebook vouched for it so I got one. It's definitely quality!
Yeah hopefully the 3.285 high compression pistons will add some power.
And yes I got the TT266 (AKA 270) cam and tune! Paired with the JE pistons, AEG exhaust and intake manifolds should make a peppy aba!
Just waiting to get the block back from the machine shop!
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62 Ragtop Project (Anthracite Grey)
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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: Sun Nov 19, 2023 6:03 pm Post subject: Re: ABA Vanagon Conversion |
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Not a very interesting update, but here's an update. I've been trying to find time to work on the engine and tonight I found some time. Today I measured my piston diameter to bore diamter clearance, and I'm sitting at .003" to .0035" on each cylinder. The pistons called for .0033", so I think I should be should be good to go.
Next I'll be setting my piston ring end gap.
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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
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rogertj
Samba Member
Joined: October 07, 2008
Posts: 505
Location: Tijuana, Baja California. Mexico
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| Posted: Tue Nov 21, 2023 3:24 am Post subject: Re: ABA Vanagon Conversion |
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| vw62kid wrote: |
Not a very interesting update, but here's an update. I've been trying to find time to work on the engine and tonight I found some time. Today I measured my piston diameter to bore diamter clearance, and I'm sitting at .003" to .0035" on each cylinder. The pistons called for .0033", so I think I should be should be good to go.
Next I'll be setting my piston ring end gap. |
Happy for you my friend that you are doing the appropriate build for this kind of engine, keep up the good work!
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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?
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Wed Dec 13, 2023 12:07 pm Post subject: Re: ABA Vanagon Conversion |
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I got another small step forward on the build yesterday. I calculated the piston ring end gap. The top ring should be at .0147", and the second ring should be at .0164". So I think it's safe to put the top ring at .015" and the second ring at .017". Hopefully the next post will be pictures of the rings getting gapped.
Talking to a few ABA guys on Facebook, they told me according to my build it would be beneficial to run a standalone ecu. I have no experience or knowledge of standalone ecus, so I have a lot to learn. I even messaged techtonic tuning to get their opinion on how I should handle tuning.
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59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
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valvecovergasket
Samba Member
Joined: October 10, 2018
Posts: 1492
Location: pnw
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| Posted: Wed Dec 13, 2023 2:02 pm Post subject: Re: ABA Vanagon Conversion |
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theres a lot of MS info for ABAs out there, fairly easy setup wise as theres base tunes all over the place and you have a built in crank trigger already so theres nothing else required to get clean rpm pickup.
add in closed loop idle and closed loop AFR and you could make a rather tidy daily driver.
i would recommend MS3 if youre going that route with all the closed loop stuff, there were a lot of changes that made tuning closed loop a lot more robust in MS3 v the older MS2 stuff
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vw62kid
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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 Jan 01, 2024 7:42 pm Post subject: Re: ABA Vanagon Conversion |
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I got around to measuring my pistons rings. All the top rings are perfectly at .015", no work needed on those. However, my second rings are at .024" and they're supposed to be at .017". I think I may have been sent the wrong 2nd rings. I'll have to contact JE or USP and see what can be done about this. My assumption is they sent me 2nd compression rings for 3.24 bore instead of the 3.287 bore I have.
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90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
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Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Tue Jan 30, 2024 5:36 am Post subject: Re: ABA Vanagon Conversion |
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They sent me out another set of rings! I measured the eng gap on the new set of rings and they are giving me the same exact issue. I triple checked my measurements and everything seems to be done correctly. So I called JE and they told me to just run them. They told me the 2nd compression ring is for oil, not compression. Being my first time ever hearing this I gave total seal a call. They told me the same thing but with a little more information. The 2nd compression ring is 70% oil management, 30% compression. Still, with my rings having a gap bigger than what a +1000hp nitrous build calls for, I decided to go with total seals gapless 2nd compression ring instead. More details and pictures to come when I receive them.
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90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Sun Feb 18, 2024 2:27 pm Post subject: Re: ABA Vanagon Conversion |
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Alright, I finally got around to working with these gapless piston rings from total seal. I first re-measured my top rings from JE, and for my comfort I'm going to open up the gap by .001" which should set it at .015".
Total seal calls for a .015" gap for their rings. The gapless 2nd rings are made of two parts. The thicker ring is sitting at .023", and the thinner ring is a real tight .016". The JE spec sheet called for .017", so I'm going to set these to .017" to be safe. Since they are "gapless" it shouldn't hurt going a little bigger.
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90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
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Joined: January 20, 2013
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Location: Topeka, KS
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Sat Mar 02, 2024 12:54 pm Post subject: Re: ABA Vanagon Conversion |
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Just set my gapless ring end gaps for the second compression rings. One of the rings was a bit bigger than the rest fresh out of the box. Im going to run it since they're gapless, second rings are 80% oil management, and JE&Total Seal said to run my other rings that were at .024.
Cyl 1 - .018"
Cyl 2 - .0185"
Cyl 3 - .022"
Cyl 4 - .019"
Now onto the oil rings!
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90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
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Location: Topeka, KS
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vw62kid
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Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Tue Mar 19, 2024 5:52 pm Post subject: Re: ABA Vanagon Conversion |
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Putting on the cleaned pistons/rings onto the cleaned rods for engine assembly.
Anyone have any tips on what I should do to my cylinder walls during the cleaning process? I was thinking about starting off with dawn dish soap and a green scotchbrite. Do a light scrub with that then move to ATF with a lint free rag. After that finish it off with dawn dish soap and a lint free rag. Then lightly coat with WD40.
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59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 89
Location: Topeka, KS
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| Posted: Fri Mar 29, 2024 9:51 am Post subject: Re: ABA Vanagon Conversion |
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Getting the engine block prepared for installation of the intermediate shaft bearings. Does anyone have any information on what bit you used to press these bearings in? Engine will be cleaned before installation, its still covered it crud from the machine shop. I'm just mocking everything up.
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90 Vanagon tin-top ABA convserion...work in progress
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Vanagon Nut
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Joined: February 08, 2008
Posts: 10379
Location: Sunshine Coast B.C.
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| Posted: Fri Mar 29, 2024 10:44 am Post subject: Re: ABA Vanagon Conversion |
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| vw62kid wrote: |
| ....Does anyone have any information on what bit you used to press these bearings in? |
You might find info on that searching VW diesel engine re builds here.
I don't know why but the machine shop I used screwed up their first attempt at installing the IM shaft inner bearing. i.e. I could see installing that part as being a bit tricky.
Neil.
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1988 West DIY 50º ABA
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