Different Way of Machining Big Bore T4 Heads

[Ohio Tom]

McMaster Carr sells stainless steel O-rings in every size.

Use them often to seal plastic die tooling.
They can take 20,000psi of pressure.

[Wreck]

A video on you tube . timely !

https://www.youtube.com/watch?v=HGaNgcSSn-k

[Vanapplebomb]

Tom, I looked at McMaster a while back, and those stainless o-rings did not come in large enough sizes… at least where I was looking. Maybe they are in a different category.

Wreck, aren’t both of those methods for use with copper gaskets? Crushing them into a mating groove? I have seen the wire trick used on Cummins engines before.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Wreck]

no just a flat 1x5.5mm copper gasket . I cut them from a sheet of Copper . just used a jig saw to rough cut , then a sanding drum on a drill for the ID and a linishing belt on the OD .

What is very important for a good seal is that the cylinders are 100% even . A tip given by a few good engine builder is to use what ever sealant you use on the cylinder bases . torque up the heads , then after the sealant is cured , carefully remove the heads and make sure the tops of the 2 cylinders are flat with a straight edge . If it means shimming a cylinder .002" then thats what you do and try the whole process again till the straight edge is flat .

[Bad bug]

Wreck seems like your process worked because i don't see any evidence of leaks on the cylinders.

[Bills914-4]

Here's some pic's of a modification I did a few years ago , the motor is a 2.5L
80 x 100 the heads are 1700 which have a 100mm bore for the 90mm cyl.
the sealing ring is 304 ss .078W x .100H flat on
the head side & radius on the cylinder side , it will have .040 deck
I'm hoping to push 20+ lbs. of boost , Bill D.

I have some pic's on shoptalk

https://shoptalkforums.com/viewtopic.php?f=3&t=150581&sid=406bead00c583a08e32914f3c76d1da4

1700 type 4 heads 42x36

100mm nickies

100mm pistons & protrusion

_________________
2800cc 914-4
TwinPlugs & MegaSquirted
Now Boosted 7-10 psi
Weekend Therapy

[Vanapplebomb]

That is EXACTLY what I had in mind!
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Vanapplebomb]

One of the problems I am having is finding a 103mm piston with the top compression ring far enough down from the crown to make this work. There are loads of 103mm pistons out there from aftermarket VW to Chrysler HEMI engines. Finding something where the crown can extend out of the cylinder by 6mm or so while still keeping the compression ring in the cylinder is a sticking point.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[nextgen]

Wreck and all you guys, reading all the experimentation that has been done since the 1990 when most of the VW guys did not have clue about T-4 engines.

The few that did, well it was mostly negative information that was passed around.

I myself had no clue till I saw what my 914 could do and was lucky to get a New T-4 training engine.

Extremely happy to see you guys still going strong with engine improvements.

_________________
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The TYPE IV UPRIGHT CONVERSION MANUAL
BEETLE MAGNETIC DEFLECTOR SHIELDS
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[Vanapplebomb]

Never settle, Joe

Always something to test and learn from.

Thank you for being one of the early pioneers in the states, developing affordable diy upright conversions. Your work paved the way for many who may otherwise have dismissed the T4 conversation.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[nextgen]

Thanks I really appreciate that!!

What you said "always something to learn" especially stands out when you think how old the T-1 especially has been around and for generations have tried to find what we think is how to make it better.

Still selling the manual, so must be a lot of barn finds, ha

Thanks again
Joe.
_________________
email: [email protected]
The TYPE IV UPRIGHT CONVERSION MANUAL
BEETLE MAGNETIC DEFLECTOR SHIELDS
LETS TALK DUBS https://www.youtube.com/results?search_query=joe+cali+ghia https://letstalkdubs.libsyn.com/ep-200-joe-cali-ty...qI3xJTCzjs

[Wreck]

My first conversion was done in the late eighties , the main person I got parts from was of Czech origin and used to import second stuff from Europe . He made up the kit for me .
A lot of development was done during the Super Vee days . Then Kafer Cup in Europe .
Pistons are an issue , getting what you want , I would like a 4032 forging in the 103.5 (4.065”) range with similar pin height to what AA supply with their kits , with a 22mm pin . Also with the compression ring above the pin .
Not going to happen with an off the shelf item .

[nextgen]

Applebomb, Wreck,
you guys made me think.
How do I advertise my manual-- HVW'S and VW Trends had pagers of Clubs world wide, No internet, just phone nubers and addresses. I sent out over 100 letters with my two page introduction. Also to Magazines world wide. Reviews were done in many countries.

That I hows I met Joe of DTM fame, Mike Sharp of Sharpbuilt, BAS of German.

Funny, I just came 30 years full circle. My first ad in VW Trends. 1993 No Website or phone number, just a PO Box. Check out the ad below mine for a complete bug restoration. I guess that was expensive then when Chris Vallone, sells his from 40k to 80k

I just released my first new advertisement and it is out 29 years later. I think, this month. They said the April issue.


With Just a email address. ha!

_________________
email: [email protected]
The TYPE IV UPRIGHT CONVERSION MANUAL
BEETLE MAGNETIC DEFLECTOR SHIELDS
LETS TALK DUBS https://www.youtube.com/results?search_query=joe+cali+ghia https://letstalkdubs.libsyn.com/ep-200-joe-cali-ty...qI3xJTCzjs

[Vanapplebomb]