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Mr. Okrasa 
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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 Posted: Sun Sep 03, 2023 10:06 pm Post subject: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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! 
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint 
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com
Last edited by Mr. Okrasa on Tue Sep 12, 2023 12:19 pm; edited 1 time in total |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 10169
Location: Pearl River, NY
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| Posted: Mon Sep 11, 2023 12:38 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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| 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? |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Mon Sep 11, 2023 1:10 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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| 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
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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wdfifteen
Samba Member
Joined: January 26, 2019
Posts: 638
Location: Ohio
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| Posted: Mon Sep 18, 2023 3:03 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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| Watching this thread. This should be interesting. |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Mon Sep 18, 2023 10:24 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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Fresh 10/10 crankshaft assembly that has been balanced along with conn. rods ready to assemble.
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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Kafer_Mike
Samba Member
Joined: June 23, 2004
Posts: 383
Location: Noblesville, IN
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| Posted: Tue Oct 10, 2023 10:06 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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That's pure mechanical art. Following and can't wait to see the finished engine.
_________________
Kafer_Mike
Build 'em fast...or let 'em sit. |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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alanhall
Samba Member
Joined: February 18, 2006
Posts: 120
Location: Northern California
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| Posted: Tue Oct 17, 2023 7:08 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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| 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 |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Tue Oct 17, 2023 9:01 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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| 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.
Link
Link
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Wed Oct 02, 2024 8:27 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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......
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Sun Oct 13, 2024 9:52 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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...........
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Tue Nov 26, 2024 9:46 am Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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.......
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Wed Dec 04, 2024 12:46 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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". 
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Sat Dec 07, 2024 11:23 pm Post subject: Re: 1953 Super 1500cc typ 528 / 2pc. Complete Eng. Build / John T. |
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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.
_________________
See my Instagram: https://www.instagram.com/okrasa/
1959 VW Karmann Ghia Coupe / Bamboo-Green / Denzel 1300cc / OG. owner, paint
Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE
VW www.Okrasa.com
356 www.PreA356.com |
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Mr. Okrasa
Original Old Speed
Joined: May 20, 2000
Posts: 743
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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