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1968 Deluxe Build
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bally
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PostPosted: Thu Oct 31, 2019 3:30 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Congratulations! From what I've seen you do on this thread it sounds to me like you'll be well suited to the new job! I look forward to more updates! Cheers. Dave
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PostPosted: Wed Oct 30, 2019 9:17 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Thanks Kent! I'm excited to put in the hard work Very Happy
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PostPosted: Wed Oct 30, 2019 5:17 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Congratulations Tman!
That sounds like it can be a lot of fun Dancing and a lot of hard work. d'oh!
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PostPosted: Wed Oct 30, 2019 5:04 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Little personal update: I got a job at a VW restoration shop here in Santa Cruz and I'm loving it so far! Hopefully this is just the beginning Wink

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PostPosted: Mon Sep 02, 2019 10:26 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Little update on that SVDA I got a couple years ago. It just recently crapped out on me. The upper shaft where it is press fit to the advance mechanism came unpressed and got wallered out so that it can no longer be fit back on. This resulted in the distributor not having any advance and being locked out at minimum advance. Luckily I had a spare 009 that I have in there now and luckily this issue didn't hurt my new engine. The 009's flat spot is much less noticeable now with the dual webers so I can tolerate driving with it. Probably going to eventually get something else but not for awhile, and it will most likely be something like a 010 or another old bosch. I could probably fix the Chinese SVDA with some welding but I'm kind of over trusting it at this point. So I guess this is more of a PSA to people about those SVDA's out there (fyi, I had the pertronix flame thrower SVDA from ACN), and for the others that already knew to stay away from them I guess you could tell me "I told you so"
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PostPosted: Fri May 31, 2019 11:32 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Spike0180 wrote:
Thank you. I've been eyeing that setup since my belt broke last year. Why dont you suggest it?


It takes awhile to get it aligned perfectly. The instructions I got with my MST setup tell you to do it wrong, which I figured out after it threw a belt. Not only do you have to get the pulleys each out the same amount, you have to make sure they are both at the same angle. I had to shim up my alternator in order to get it to be at the same angle as the crank pulley. Second, you have to get you tension pretty dead on. Since you engine grows when it's hot, the distance between the two pulleys increases, therefore tightening the belt. If you set it up at the perfect tension cold, it will be too tight when hot and cause excess wear on the tensioner bearing (as well as the alternator/generator). I learned this the hard way by the Chinese bearing supplied with the kit seizing and the belt burning itself up on the tensioner not spinning. I have since replaced the bearing with a high quality Japanese bearing. I have to run the belt pretty loose cold in order for it to be tensioned properly when warm. You also have to get the tensioner exactly perpendicular with the pulleys otherwise the belt can track in one direction and possibly track off the tensioner or into the tensioner bracket and eat up the side of the belt. All this for the hefty price tag that these kits fetch is defiantly not worth it in my opinion.

In regards to blowing up the fan, it is my understanding that it is not high rpm that blows up the fan, it is sudden accelerations of engine speeds such as a very fast, aggressive downshift. So if you aren't driving it like a race car, I think you'd be fine with an un-welded fan.

I still carry a spare serpentine belt and don't have any extra peace of mind, but people dig the way it looks when I pop the engine hatch Rolling Eyes
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PostPosted: Fri May 31, 2019 8:39 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Spike0180 wrote:
Trashman wrote:
Also one more thing to anyone interested in a serpentine-style setup on their type 1 motor, I don't recommend it. After running the setup for about eight months now, it's really not worth it. I would just stick with the ol' v-belt, carry a spare, and call it a day.


Thank you. I've been eyeing that setup since my belt broke last year. Why dont you suggest it?


It’s my understanding that the V-Belt is designed to slip at high RPMs and the serpentine does not. Which may cause a non welded fan to explode.
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Spike0180
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PostPosted: Fri May 31, 2019 7:53 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Trashman wrote:
Also one more thing to anyone interested in a serpentine-style setup on their type 1 motor, I don't recommend it. After running the setup for about eight months now, it's really not worth it. I would just stick with the ol' v-belt, carry a spare, and call it a day.


Thank you. I've been eyeing that setup since my belt broke last year. Why dont you suggest it?
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Manfreds78bay
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PostPosted: Fri May 31, 2019 1:29 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Trashman wrote:
Manfreds78bay wrote:
Wow! Man...someone needs to snap this guy up and get him his own shop.


lol. Yeah I'm looking for investors Laughing

I've been looking for some sort of shop space around here that's affordable. Not really a thing. I am going to have to figure something out soon though because I'm moving and the place that I'm going to is even worse for doing any kind of automotive work.


That sucks! You should open a shop out of a van and call yourself the first Gorilla Mechanic. Twisted Evil
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Trashman
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PostPosted: Fri May 31, 2019 9:20 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Also one more thing to anyone interested in a serpentine-style setup on their type 1 motor, I don't recommend it. After running the setup for about eight months now, it's really not worth it. I would just stick with the ol' v-belt, carry a spare, and call it a day.
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PostPosted: Fri May 31, 2019 9:14 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Manfreds78bay wrote:
Wow! Man...someone needs to snap this guy up and get him his own shop.


lol. Yeah I'm looking for investors Laughing

I've been looking for some sort of shop space around here that's affordable. Not really a thing. I am going to have to figure something out soon though because I'm moving and the place that I'm going to is even worse for doing any kind of automotive work.
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PostPosted: Fri May 31, 2019 9:10 am    Post subject: Re: 1968 Deluxe Build Reply with quote

metz wrote:
So cool. Engine build looks great. How much hp were you aiming at?


Thanks! Your guess is as good as mine. I wasn't really considering hp when putting this together, I was really only concerned with low end torque so i can load the bus up with stuff and hit the mountain roads in 4th gear. And let me tell you, it now has no problem with that. I can accelerate in 4th up a hill with ease.

asiab3 wrote:
Are you saying the car levels itself left to right and front to back???

I just went from “I wanna but this guy a beer” to “I want to modify my bus now.”


Hell yeah it does! Stop by Santa Cruz on your tour and we can chop your shit up on the street in front of my house Laughing I'm moving on Tuesday so we can make a racket and not care if the neighbors like me lol.

richparker wrote:
Engine looks great! I have a few questions. Who’s heads, what crank, what.l clutch, why didn’t you a stock fan housing and did you weld the fan to withstand that belt set up?


Aircooled.net stock valve L3 heads that I opened up the chambers a bit and did a little bit removing the casting marks in the ports (they didn't need much at all). I went with stock valve heads because I wanted a low revving motor, not a screamer. With the smaller valves and ports, it keeps the air velocity higher down low which more or less equals more torque. This does in turn sacrifice cfm up high in the rpm's, but I'll really never be up there so it's a sacrifice that I was willing to make. For the crank I've got Kuhltek's 74mm 4340 chromoly crank. Reason for this choice being that they seem to make one of the only 4340 cranks in 74mm (everyone else seems to only make it in 4140). Didn't use the stock fan shroud for two reasons, one being I'm no longer running heat with that diesel heater that I still need to finish, and two being just being looks. And yes the fan is welded. When I got the bus, the fan spacing was off and it rubbed on the shroud and wore down the tabs on the fan veins so I had to weld it when I fixed the spacing issue.
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PostPosted: Fri May 31, 2019 7:53 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Engine looks great! I have a few questions. Who’s heads, what crank, what.l clutch, why didn’t you a stock fan housing and did you weld the fan to withstand that belt set up?

I remember when you set up the self leveling, pretty cool! Most of us just use lynx leveling blocks.
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PostPosted: Fri May 31, 2019 7:46 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Wow! Man...someone needs to snap this guy up and get him his own shop.
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bally
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PostPosted: Fri May 31, 2019 1:36 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Epic update. Engine looks superb! Good luck getting it fully dialled in 😊
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PostPosted: Fri May 31, 2019 12:44 am    Post subject: Re: 1968 Deluxe Build Reply with quote

Are you saying the car levels itself left to right and front to back???

I just went from “I wanna but this guy a beer” to “I want to modify my bus now.”

Nice work!
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PostPosted: Fri May 31, 2019 12:08 am    Post subject: Re: 1968 Deluxe Build Reply with quote

So cool. Engine build looks great. How much hp were you aiming at?
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PostPosted: Thu May 30, 2019 10:12 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Here comes a long due update on the bus. As I was talking about before I have been working on a new engine for the bus. To be specific, I've been working on a 1968cc engine. The combination that makes this size is a 74mm stroker crank with 92mm pistons and cylinders. I went with 92mm thick wall cylinders because they are super thick, thicker than the stock ones, which are good for the heat that the extra load a bus creates for the engine compared to a bug. Everything in the rotating assembly was stack balanced and all of the reciprocating parts were balanced to each other. I used a stock weight flywheel (drilled for the 8-dowel crank). If you have any questions about any other components I used and why I used them, just shoot me a pm. Here's comes a massive photo dump of some of the process.

First thing I did with the new as41 case was to change the brazilian oil pickup for a german one (brazilian is grey and the german is the black one). I also ending up having to clearance the case for the larger stoke (not shown here).

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Then I drilled and tapped for full flow and smoothed out the transition in the fitting since I was bored waiting for other parts.

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Lifter grooves cut

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Oil pump inlet rounded over to have a better path to full face of the gears

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Breather box template

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First mock up

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Checking deck height determining the amount of shim needed (started with a positive deck)

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Short block assembly

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Long block assembly

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Figuring out rocker geometry (solid rocker shafts used in final assembly btw)

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Had a little mishap when my girlfriend was helping be transfer the engine from a stand to a dolly less than a foot away. Of course the mishap happened then and not when we carried it from my room to the backyard, even down stairs, lol d'oh!
Luckily I didn't have the pushrods installed!

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Full flow lines fitment around mustache bar and headers

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Oxygen sensor installed for dialing in the jetting

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Almost done

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The final product all installed!

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Took the bus on its first excursion with the new engine this week. The girlfriend and I went camping in Butano State park again. I was doing tuning along the way and was able to get a lot dialed in. The way there was far from flawless but on the way back home there weren't really any issues, although there is still some room for improvement.

Somewhere on hwy 1

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At the campsite. I bet your all stock westy camper can't level itself at the campsite can it? #2gunfire

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PostPosted: Thu Apr 11, 2019 7:46 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

Hahaha that’s good. I enjoy my Plug N Chug, probably my #1 used accessory besides my radio. Once you have the cup holders...........

Rkbbie
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PostPosted: Thu Apr 11, 2019 7:01 pm    Post subject: Re: 1968 Deluxe Build Reply with quote

I was thinking the same thing. Contemplating if I would put it up front where I have the cb radio in the picture, or on top of the doghouse and have it mount using the top four bolts so I can take it on and off when I please.

I've never owned a car that has had cupholders so it seems like blasphemy to put cupholders in an old German vehicle (but chopping them up and bagging them doesn't). Interesting internal battle here lol
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