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SkrapMetal Samba Hornblaster
Joined: January 18, 2006 Posts: 2558 Location: Dallas, TX
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Posted: Wed Sep 12, 2007 4:36 pm Post subject: How to save a case, from a case saver (pics) |
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I decided to do a little "how to" that will hopefully help someone else in the future... maybe good enough for a sticky? I have to give credit to 'rterfert' for giving me the idea, and for the help.
I started leaking oil badly, and found that a case saver on cylinder #4 was stripped out. After doing some homework, I figured either new case, or try to fix it. With having 94mm jugs, sometimes there's a price to pay.
At first glance, you can see there's a few more threads sticking out than there should be. So, first order of business.... pull the engine, remove the head.
After pulling the engine, and removing the head, I double nutted the stud and removed it. You can see just how far it had been pulled out. Since the area between the hole for the piston and the hole for the case saver is so close, tapping for new threads is simply out of the question.
To remove the case saver, I put two nuts on the end of the stud, put a big nut on the end of the case saver, then reinserted the stud and butted the nuts up together so I could loosen and remove the case saver. As you can see, most of the threads from the case came out with the case saver.
I took the case saver, and an extra head stud washer (since they are thick) and went to an experienced welder and had him weld the nut to the back of the case saver.
For this part, you'll need long thin fingers (or needlenose plyers). I applied a little loctite (the blue removable kind) to the inside of the case saver, then threaded the stud into it. After drying for a day, I double nutted the end of the stud, and slowly turned the case saver inward until it was all the way in.
As you can see here, the washer doesn't exactly clear for the piston, so I had to draw a line with a marker so I knew what to grind off. I turned the pulley slowly with a wrench and found that I also had to grind a little from the right side because the back of the rod from cylinder #2 would hit it.
Finally, I got the engine to turn over completely, without anything hitting or rubbing. SO essentially... it's fixed. Just have to reattach the head, torque it, and hope that it holds. While this may work for some locations on the engine, I cannot guarantee it will work in others.
So now I have to ask one question....
Does anyone happen to know exactly how much parts expand with heat and all? The reason I ask is because I feel that the back side of the rod from cylinder #2 might expand and hit the washer thats attached to the case saver. I know thats not an easy question to answer but a little truth wouldn't hurt. _________________ oo9less since 2007
-72 Ghia- |
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SRP1 Samba Member
Joined: January 06, 2007 Posts: 4340
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Posted: Wed Sep 12, 2007 4:47 pm Post subject: |
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SkrapMetal
You will need .040" to be safe between moving and non moving parts and that goes for most any engine. I have seen less but that is considered the absolute safe minimum.
Hope this helps. |
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SkrapMetal Samba Hornblaster
Joined: January 18, 2006 Posts: 2558 Location: Dallas, TX
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Posted: Wed Sep 12, 2007 5:54 pm Post subject: |
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SRP1 wrote: |
SkrapMetal
You will need .040" to be safe between moving and non moving parts and that goes for most any engine. I have seen less but that is considered the absolute safe minimum.
Hope this helps. |
Wow, I really didn't think anyone would know. Thanks!! I'm going to grind off a very thin layer from the washer, just to be safe, then start putting it all back together again. I'll post a video when I'm through, if I don't run into any problems. _________________ oo9less since 2007
-72 Ghia- |
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rterfert Samba Member
Joined: October 08, 2003 Posts: 1419 Location: Yuma Arizona
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Posted: Wed Sep 12, 2007 6:41 pm Post subject: |
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Looks like a winner |
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Towel Rail Horizontally Opposed
Joined: April 15, 2005 Posts: 4622 Location: SE CR IA US NA PE
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Posted: Wed Sep 12, 2007 6:42 pm Post subject: |
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I like it. Hopefully this keeps the leak at bay, too. _________________ 1974 Thing -- under the knife
1967 Beetle -- spring/summer/fall driver
1996 Subaru OBW (EJ22, 5-speed, AWD) -- winter car, 3-seasons "don't feel like biking today" car
049 > 070 > 053 > 009 |
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keifernet Samba Search & Rescue
Joined: May 11, 2002 Posts: 19395 Location: Samba Center for Behavioral Science
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Posted: Wed Sep 12, 2007 6:46 pm Post subject: |
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Seeing as how it was cut for the larger cyls that is your only shot VS specialty welding and re machining the case... I hope it holds for you... |
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rterfert Samba Member
Joined: October 08, 2003 Posts: 1419 Location: Yuma Arizona
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Posted: Sun Oct 21, 2007 8:03 pm Post subject: |
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Well is it running yet
Iquiring minds wish to know |
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jeff denham Samba Member
Joined: January 14, 2006 Posts: 780 Location: calif
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Posted: Sun Oct 21, 2007 8:39 pm Post subject: |
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good job. thats using the old noodel. JD. |
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Rowroy Samba Member
Joined: November 07, 2006 Posts: 1012 Location: The ass of nowhere
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Posted: Mon Oct 22, 2007 5:24 am Post subject: |
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That's a great idea. _________________ Suicide is man's way of telling God, "You can't fire me; I quit!" - Bill Maher |
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SkrapMetal Samba Hornblaster
Joined: January 18, 2006 Posts: 2558 Location: Dallas, TX
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Posted: Tue Oct 23, 2007 3:32 pm Post subject: |
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rterfert wrote: |
Well is it running yet
Iquiring minds wish to know |
Not running yet, but the head is on, torqued up, and it's holding. I'm waiting on some gaskets, and a jack that goes a bit higher, so maybe a week or so. The real test is yet to come. _________________ oo9less since 2007
-72 Ghia- |
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Stripped66 Samba Member
Joined: May 31, 2005 Posts: 3470 Location: Charleston, SC
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Posted: Tue Oct 23, 2007 4:06 pm Post subject: |
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Great idea!
Now...what do you do when you pull the threads out of the deep-stud on the #3 cylinder? _________________
66brm wrote: |
Bodacious wrote: |
Why not just make a custom set of wires with a Y splice in them. Then you could just run one distributor. |
I don't think electrickery works that way |
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rterfert Samba Member
Joined: October 08, 2003 Posts: 1419 Location: Yuma Arizona
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Posted: Tue Oct 23, 2007 5:59 pm Post subject: |
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Stripped66 wrote: |
Great idea!
Now...what do you do when you pull the threads out of the deep-stud on the #3 cylinder? |
Should be able to do the same thing? |
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miniman82 Samba Swamp Donkey
Joined: March 22, 2005 Posts: 9515 Location: Southern Maryland
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Posted: Tue Oct 23, 2007 11:25 pm Post subject: |
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Stripped66 wrote: |
Great idea!
Now...what do you do when you pull the threads out of the deep-stud on the #3 cylinder? |
swap in a single 10mm stud? _________________ Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=212747
Glenn wrote: |
satterley_sr wrote: |
I just wanted to bitch but I'm getting no sympathy. |
Welcome to the Samba. |
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SkrapMetal Samba Hornblaster
Joined: January 18, 2006 Posts: 2558 Location: Dallas, TX
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Posted: Sun Nov 04, 2007 3:48 pm Post subject: |
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...and it lives again!
Link
Took it out for a 30 min drive on the interstate and around town. Runs and drives well. No oil leaking from the repair area. Thanks to all who helped me! _________________ oo9less since 2007
-72 Ghia- |
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keifernet Samba Search & Rescue
Joined: May 11, 2002 Posts: 19395 Location: Samba Center for Behavioral Science
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Posted: Sun Nov 04, 2007 3:52 pm Post subject: |
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miniman82 wrote: |
Stripped66 wrote: |
Great idea!
Now...what do you do when you pull the threads out of the deep-stud on the #3 cylinder? |
swap in a single 10mm stud? |
Sink a stud insert in it??? There are several larger OD pitch thread sizes to choose from to fix that one. |
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SRP1 Samba Member
Joined: January 06, 2007 Posts: 4340
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Posted: Sun Nov 04, 2007 8:56 pm Post subject: |
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Can I have a Hell Ya! Good job, and great idea.
Looks and sounds great. |
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