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Jimmy111
Samba Member
Joined: October 05, 2006
Posts: 2643
Location: Wyoming
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 Posted: Tue Jan 08, 2008 9:24 am Post subject: |
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| Generally you heat it up to about 400 degrees then weld it. However it will still lose the heat treatment in the area surrounding the weld. This might be a good thing in that location because it makes the material in that area more ductile. |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Tue Jan 08, 2008 7:22 am Post subject: |
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My machinist heats up the case for about 6 hours in an oven (? Temp), welds the plate in behind # 3, puts the case back into the oven, turns the oven off and lets cool overnight slowly.
He has done 4 cases for me and I cannot measure any heat damage to the main bearing adjacent to the patch. I am measuring to 0.0005 inch.
I have measured the thickness of the step cut of a 94 mm hole to the #3 area and I remember it only being 0.090 to 0.095 inch thick. No wonder it could crack, exspecially if you have not balanced the engine and the high RPM vibrations can cause a crack.
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Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race
Everyone is gifted. Some just do not open the package.
Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone |
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stealth67vw
Samba Member
Joined: January 22, 2004
Posts: 1872
Location: Grass Pants, Orygun
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Terry Cloyd
Banned
Joined: March 23, 2004
Posts: 2218
Location: Valley Center "SO CAL"
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| Posted: Mon Jan 07, 2008 9:59 pm Post subject: |
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| stealth67vw wrote: |
| German Fuelie case. The golden child. Yes I know. |
So big guy.........Answer the  weld or not |
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stealth67vw
Samba Member
Joined: January 22, 2004
Posts: 1872
Location: Grass Pants, Orygun
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Terry Cloyd
Banned
Joined: March 23, 2004
Posts: 2218
Location: Valley Center "SO CAL"
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| Posted: Mon Jan 07, 2008 9:49 pm Post subject: |
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Did you know that they made a case that filled the deep set # 3 stud  Yes no welding |
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stealth67vw
Samba Member
Joined: January 22, 2004
Posts: 1872
Location: Grass Pants, Orygun
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Terry Cloyd
Banned
Joined: March 23, 2004
Posts: 2218
Location: Valley Center "SO CAL"
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| Posted: Mon Jan 07, 2008 8:58 pm Post subject: |
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| You need to weld it |
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Jimmy111
Samba Member
Joined: October 05, 2006
Posts: 2643
Location: Wyoming
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| Posted: Mon Jan 07, 2008 8:39 pm Post subject: |
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The place that you call a defect is normal. That is where the sprue or heat riser was attached when they poured the casting to prevent shrinkage at that spot due th the excessive amount of aluminum there. The oxides and other impuritiew will float and settle in the highest and hottest part of the casting. This case was probably poured a little cold but no structural defect.
| fitnessforyoutoo wrote: |
| fitnessforyoutoo wrote: |
| ashman40 wrote: |
Here's a pic I found in the gallery that might make it easier for those that have never seen it.
Actually, this is a new aluminum case that comes cast w/ a solid area behind #3 instead of welding it in, but you can see the webbed area to the right of the crank on Glenn's case is a solid mass on this one.
[url]
[/url] |
I don't think I would trust a case with a bad casting like that one because if there is one bad spot there probably are others in the galleys or some other critical part where you cant see it until the motor blows up. |
Do you see in the picture where the back of #3 is machined and the casting left a void? If you see that there can be other places inside the case where you cant see them. Ask muffler Mike about how many cases he went through to find one that was repairable. Or just go to his web site mufflermike.com and read about it.
I found his site very informative and it helped me to get back up to speed after a 10 year layoff from my turbo bug. |
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henrym
Samba Member
Joined: August 19, 2006
Posts: 1010
Location: Marina Del Rey, California
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| Posted: Mon Jan 07, 2008 7:50 pm Post subject: |
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It has been mentioned to me by a couple of people that a case that is welded behind #3, unless done perfectly, should be line bored as it is really tough to do this without distorting the case.
I ask becasue my case is a brand new AS41, welded behind #3, f/flowed, clearenced, bored, big-studded, etc.. I bought it as a package deal (otherwise I would not had it align bored).
Before I go to the trouble to assemble this engine (which I have a lot of $$$ into), should I have the bore touched up on it? I don't mind having this done it it save me headaches later.
Opinions welcome....
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cal63look
Samba Member
Joined: January 14, 2006
Posts: 1027
Location: Colorado
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| Posted: Sat Aug 18, 2007 4:14 pm Post subject: |
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Oops, i should have said repainted 010, my bad, dont want to confuse anybody!
You know which one it is Glenn, remember |
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Glenn 
Mr. 010
Joined: December 25, 2001
Posts: 79441
Location: Sneaking up behind you
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| Posted: Sat Aug 18, 2007 3:46 pm Post subject: |
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| cal63look wrote: |
| Glenn wrote: |
| cal63look wrote: |
| (please dont mind the clear cap, lol, only for mockup) |
If you say so. |
Or should i say the 009-  
Now if that person ever sends my blue 010............. |
Bosch 010 were never blue, only the 019.
_________________
Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
עַם יִשְׂרָאֵל חַי |
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cal63look
Samba Member
Joined: January 14, 2006
Posts: 1027
Location: Colorado
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| Posted: Sat Aug 18, 2007 3:45 pm Post subject: |
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| Glenn wrote: |
| cal63look wrote: |
| (please dont mind the clear cap, lol, only for mockup) |
If you say so. |
Or should i say the 009-
Now if that person ever sends my blue 010............. |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79441
Location: Sneaking up behind you
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| Posted: Sat Aug 18, 2007 3:42 pm Post subject: |
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| cal63look wrote: |
| (please dont mind the clear cap, lol, only for mockup) |
If you say so.
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
עַם יִשְׂרָאֵל חַי |
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cal63look
Samba Member
Joined: January 14, 2006
Posts: 1027
Location: Colorado
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| Posted: Sat Aug 18, 2007 3:41 pm Post subject: |
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Here is a picture of my case. I think cb hooked me up, i didnt pay for it, but i paid for almost everything else (bore,clearenced 82mm, full flow) Looks different than the one's above though. (please dont mind the clear cap, lol, only for mockup)
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79441
Location: Sneaking up behind you
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| Posted: Sat Aug 18, 2007 3:40 pm Post subject: |
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| cal63look wrote: |
| miniman82 wrote: |
| Doesn't Glenn's engine use thick 92's? Same size hole in the case as 94's... |
I guess i'll speak on Glenns behalf - hope you dont mind 
Yes he is running the thickwall 92's but the base it turned down to fit into the OG 90.5 size bore
You can also do this with 94's (turned down bases) but the cylinder heads are still opened up for the 94's |
Exactly
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
עַם יִשְׂרָאֵל חַי |
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cal63look
Samba Member
Joined: January 14, 2006
Posts: 1027
Location: Colorado
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| Posted: Sat Aug 18, 2007 3:32 pm Post subject: |
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| miniman82 wrote: |
| Doesn't Glenn's engine use thick 92's? Same size hole in the case as 94's... |
I guess i'll speak on Glenns behalf - hope you dont mind
Yes he is running the thickwall 92's but the base it turned down to fit into the OG 90.5 size bore
You can also do this with 94's (turned down bases) but the cylinder heads are still opened up for the 94's |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79441
Location: Sneaking up behind you
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| Posted: Sat Aug 18, 2007 2:39 pm Post subject: |
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Sand cast... easy to have voids.
_________________
Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
עַם יִשְׂרָאֵל חַי |
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fitnessforyoutoo
Samba Member
Joined: December 22, 2005
Posts: 46
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| Posted: Sat Aug 18, 2007 2:24 pm Post subject: |
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| fitnessforyoutoo wrote: |
| ashman40 wrote: |
Here's a pic I found in the gallery that might make it easier for those that have never seen it.
Actually, this is a new aluminum case that comes cast w/ a solid area behind #3 instead of welding it in, but you can see the webbed area to the right of the crank on Glenn's case is a solid mass on this one.
[url]
[/url] |
I don't think I would trust a case with a bad casting like that one because if there is one bad spot there probably are others in the galleys or some other critical part where you cant see it until the motor blows up. |
Do you see in the picture where the back of #3 is machined and the casting left a void? If you see that there can be other places inside the case where you cant see them. Ask muffler Mike about how many cases he went through to find one that was repairable. Or just go to his web site mufflermike.com and read about it.
I found his site very informative and it helped me to get back up to speed after a 10 year layoff from my turbo bug.
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1956 2000cc 30 psi + boost, methanol EFI NOS chop top turbo sedan under construction |
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57 Rag
Samba Member
Joined: October 24, 2006
Posts: 1145
Location: Paradise
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| Posted: Sat Aug 18, 2007 11:45 am Post subject: |
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| fitnessforyoutoo wrote: |
| ashman40 wrote: |
Here's a pic I found in the gallery that might make it easier for those that have never seen it.
Actually, this is a new aluminum case that comes cast w/ a solid area behind #3 instead of welding it in, but you can see the webbed area to the right of the crank on Glenn's case is a solid mass on this one.
[url]
[/url] |
I don't think I would trust a case with a bad casting like that one because if there is one bad spot there probably are others in the galleys or some other critical part where you cant see it until the motor blows up. |
What bad casting are you talking about??
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57 Ragtop
84x94 86C
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