My Big Bore '40hp' build

[jasengine]

Small update:
The passenger seat is non-tilting (long story!) so I have modified the subframe so it can tilt...

[jasengine]

Not yet. Front wheels and tyres need putting on, tracking needs sorting out front and rear and there is one wing and rear quarter panel to sand and paint.
Engine is all complete and ready to run

[Rome]

Have you been able to finish up the engine hookups/exhaust and finally take this beastie for a drive?

[jasengine]

The wheel is a MOMO copy I think. 350mm diameter with an MOMO boss adapter.

Seats are Cobra classic bucket.

[Lingwendil]

What diameter wheel is that? It looks like a great fit.

What seats!? They look great!!!
_________________
73 super beetle thread http://www.thesamba.com/vw/forum/viewtopic.php?t=649622 Back on the Road!

Modify your Kadrons for SVDA http://www.thesamba.com/vw/forum/viewtopic.php?p=8115884#8115884

Cast iron VJU4BR8 SVDA reference thread- https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Need replacement filters for original Kadron aircleaners? WIX #42087 is a perfect fit, as is Napa Gold #2087!

[jasengine]

MOMO steering wheel fits nicely!

[jasengine]

I didn't use this CSP breather box in the end as it was too big to fit between the fan housing and firewall.

Original style 15' steel wheel 5.5, with 195x65 tyre

[jasengine]

Its been a while since I posted! (Divorce and life rebuilding has been a set back)

I'll post some photos when I get chance; but I've got the engine in and all the plumbing and wiring completed.

[jasengine]

It's the original SVA that was on the engine. I will probabily change it at some point to a SVDA unit if the vac from the vac take off on the drla40 is enough. I will get a pulse damper from eurocarb.com which should help smooth the pulses.
I will be doing some testing of the vacuum at some point.

[Lingwendil]

Are you using that vacuum only distributor with those carbs? How did you get the carb to give the right signal?
_________________
73 super beetle thread http://www.thesamba.com/vw/forum/viewtopic.php?t=649622 Back on the Road!

Modify your Kadrons for SVDA http://www.thesamba.com/vw/forum/viewtopic.php?p=8115884#8115884

Cast iron VJU4BR8 SVDA reference thread- https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Need replacement filters for original Kadron aircleaners? WIX #42087 is a perfect fit, as is Napa Gold #2087!

[jasengine]

Small update: Life getting in the way at the moment, so not much progress apart from wiring all the gauges up and adding a twin relay setup for the fuel pump.
Ive got to run the engine again and set the timing correctly as I have realised I read the timing light wrong; no wonder it was a little lumpy in the video above!
I'm going to take the time and set the valve gaps properly, i.e turning engine to each TDC on compression stroke etc..
Ive been pulling all the extra wiring through to the engine bay and installing the external oil cooler and fan (above gearbox), which will need a thermostatic switch inline with the feed pipe and a thermostatic sandwich plate to go in before the remote oil filter.
I can then finally get the transmission into the bug and I am going with some adjustable spring plates, so something else to buy, its never ending!

[jasengine]

Valves re adjusted, idle set almost low enough. Small video of it running...

[jasengine]

Finally, electric pump hooked up, push rod tubes sealed, fired her up and done the 20 min. run-in at 2300rpm ish. Drained oil and filled with straight Millers 30w oil with new filter. Once ive run the engine in the car and bedded the rings in I will change the oil to Millers CFS 10w40.
I need to set up the carbs next as it was running on no throttle at this speed, I think the throttles are not shutting down properly. Idle mixture needs adjusting as there was a bit of snapping when I blipped the throttle. These carbs have no idle air adjustment, so I guess its all setup with throttle position and idle mixture. I noticed the threaded oil gallery plug above the oil pressure sender was leaking slightly . So I'll need to take that out and seal it. Bit strange that.
Next, re-adjust the valves, tune the carbs then the 41 other jobs on the list!!

[jasengine]

I fired her up again on the repaired pump, but blew a fuel line off the pump outlet. I'm thinking the stroke length could have changed slightly.
Ive had enough of the mechanical pump now as I think its too risky if anything goes wrong and covers the engine in petrol (sorry I mean gas ). So I am going to install an electric pump instead: If anything goes wrong fuel feed is cut with ignition off.
I'm looking at the Facet Posi-flow pump with the 1.5 - 4.0 psi range. Anyone had experience with this type?

[jasengine]

Fuel pump repaired

I used a high tensile M3 button-head screw and turned a recessed brass washer to force the diaphragm discs together.

[jasengine]

Quoting from aircooled.net :

"Immediately bring the RPM’s up to 2000 or higher. We like to vary the RPM’s between 2000 and 3000, and do this for 15 minutes while keeping your eyes glued to the oil light!"

So perhaps I can bring it down a bit

[txoval]

New engine startup/break-in RPM's should be 2000 for 20 minutes...not 3000

[jasengine]

Pump internals:

[jasengine]

Ok on reflection, the first possible reason why the oil pressure is reading so high is the sender is a VDO unit, but the gauge is some other make... With 100psi I'm sure I would see a few other problems showing them selves.

So apart from that, I've re sealed the rod tubes on one head: I don't like these big bore spring loaded tubes, they're too wide and don't allow the seal to seat fully against the head.
I noticed a bit of flooding in one carb vent. so took the float out and re-measured the distance between float and the cover, which was about 1mm out. Both carbs need slight adjustment, so cutting a long story short it cured the flooding.....until I notice fuel pissing all over the floor! It was coming from the mech. fuel pump! On investigation and pump strip down,the metal part of the diaphragm had pulled apart. Crappy cheap replacement pump parts?? It looks like the metal discs were only pressed together. Better this happened now and not down the road!

[jasengine]

Additional:
I took the plugs out tonight and inspected them. Cylinders 1/2 were sooty, 3/4 less so. No sign of oil on them either.
I took out the oil pressure valve at the flywheel end and it was the standard spring. So perhaps this high oil pressure is due to the cold 30w oil and 3000rpm. The smoke, incidentally was not blue, more grey. I will fire her up again tomorrow and check again, maybe lower revs to 2500 and see if there is any change.