Valve Clearance

[kimkinzie]

Is there a standard tolerance to ensure that I don't cut too much? How much would the set screws 'ideally' protrude above the lock nut?
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'69 Ghia

[kimkinzie]

Revisited photos - there may be only a single hefty shim beneath assembly bolts. It's coming off

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'69 Ghia

[QRP]

[Brian_e]

You have multiple issues that all need to be addressed.

Order this.
https://www.amazon.com/LAIWOO-Professional-Indicat...s9dHJ1ZQ==

You will use it many times on the next engine build. You will also need to buy or build and adjustable push rod tool.

It’s hard to tell which style adjuster screws you have. They look to be either the elephant feet, or the swivel ball courier style. If they are the swivel ball style, take them all off and throw them in a swamp somewhere, and buy some elephant feet.
Pull the rockers off, and get the rocker arms cut back so the elephant feet have some room to move. Tabari does this very nicely, but you can do it on a bench grinder in a pinch.

Next get rid of all those damn shims under the rocker blocks. Start from zero. Use the indicator and the adjustable push rod to figure out your correct geometry for YOUR cam in YOUR case. Nobody can tell you what YOUR push rod length will need to be. Every engine is different depending on parts, and machine work. It must be measured.

Once you figure out the correct push rod length you can have your push rods cut down, but I would toss them in the same swamp as the adjusters. Aluminum push rods are 10x better.

After you get it all back together you will no longer have the valve cover interference issue, the nuts will be fully engaged on the studs, the geometry will be correct, the adjuster will have room to be adjusted, the valve guides will have a chance at life, it will probably be quieter, and you will have learned something.

Denting the valve covers is obviously not the cure to your multiple problems here. Don’t feel bad. This is super typical of a shade tree VW engine build. Lots of small details are always missed. Denting valve covers is a shade tree fix for a problem that shouldn’t be happening.

Brian
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www.type-emotorsports.com

[kimkinzie]

@Brian_E - brilliant summary of the entire thread, thanks a million for the link - micrometer measurement tool ordered & on way via Amazon.

The clearance issue came about only after having been able to remove valve covers and do adjustment for 1st time ever (my first VW service in 40 years) - #1-#2 was baked in place with foul gasket sealant. There have been multitudes of running issues encountered, of which this is the first work on engine internals (work so far has been on just getting it able to drive highway speeds in last 2 weeks above 4000 RPM). There are build issues and balancing problems ~everywhere~, but this is just part of the sorting process. With less that 2,000 miles on a fresh crate build, it is wonder this car is alive at all. I assume that is what you get when you value bling over running condition ...

Samba build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=763854
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'69 Ghia

[Rome]

[kimkinzie]

just for the mufflers (Amazon loves this car)

hardware in the mail:

Beck Arnley 039-6241 Tailpipe Install Kit
Exhaust Nut Set, Clearanced, Brass, Compatible with Dune Buggy

gasket kits:

Fel-Pro MS225703 Intake & Exhaust Manifold Gasket Set
Steel Stinger Gasket, for Small 3 Bolt Flange

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'69 Ghia

[kimkinzie]

[txoval]

I don't want you to take this as a smartass comment, but I recommend repairing your floor pans before driving. One big bump and you could be in big trouble

[kimkinzie]

absolutely not .. it all comes down to a matter of sequencing

I need to build some welding skills before I take on that task .. it is already on my list. I visited a local repair shop that does a *LOT* of bug restorations, fine metal welding, and detail work. The projects that they would finish for $100-$200 in a quick patch panel, tack weld, or whatever was required are long gone. They now ring the cash register at $2k-$3k a pop from insurance, and my jobs are far below their radar. I was lucky enough to find an old school welder tucked behind in our local industrial complex who is gonna charge me $20 for some seam welds on the muffler pipes. He offered quite a number of suggestions on how to get the ball rolling (local community college, etc.) but my interest was more in the types of material that could be patched (in particular Aluminum) and he led me through a short MIG tutorial. Amazing stuff. As Tony Stark says .. "I want one"


Link


yes. the pans stink, but it's not raining, and the engine take priority
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'69 Ghia

[kimkinzie]

plus .. it's only me as test pilot - the rust in floor pan is on passenger's side (previous owner might have had a heavy friend) right were the OEM seat rails should sit. I noticed that the left - right front seats were actually offset in their bolt patterns - and the PPI inspection showed that they were doing their best to avoid the rust cancer areas and place right side seat bolts in clean metal.

I could actually remove the second seat completely - it's basically there for looks and a bit of finished style. No passengers until the car is sorted. I am sitting as low as possible for handling / steering purposes, so having bolts in the pan is only a worry in wet conditions. I probably need to come up with a more permanent solution in time ...
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'69 Ghia

[RCP Phx]

I just read your other thread and all I can say is you bought a nightmare and will spend a lifetime fixing what the previous owner "sold" you. You better have a lot of cash and time for this project!

[kimkinzie]

gonna prove you soooo wrong, buddy
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'69 Ghia

[kimkinzie]

quite honestly, there is quite a lot of 'tude in forums, nowadays. I've been doing this 'Internet thing' for so long ... well ... whatever

As @kingkarmann points out:

"Ego is the anesthesia that deadens the pain of stupidity." – Dr. Rick Rigsby

https://lifeinfocus.me/2019/08/13/ego-is-the-anesthesia-that-deadens-the-pain-of-stupidity/


sooo .. who is assuming and. making an ass out of "u and me"?
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'69 Ghia

[kimkinzie]

Internet wise .. I truly roamed with the dinosaurs in case you understand what this book is all about:

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'69 Ghia

[kimkinzie]

... or a more 'modern' reference in case that is too 'old school' ....

EnglishmansDentist Exploit Analysis
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'69 Ghia

[kimkinzie]

... and maybe .. but just maybe .. I have time on my side

GBU Wizards


any questions?
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'69 Ghia

[KEGZ]

We get it. You're an old timer.

But you lost me when you referred to the Ikaika Makaki'i as "voodoo"

[QRP]

[Brian_e]