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akomjathy
Samba Member
Joined: October 15, 2004
Posts: 208
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 Posted: Wed Nov 02, 2016 11:28 am Post subject: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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I need a little bit of help. I want to build a 36 HP engine case with a big bore 83 mm p/c set. I know that I have to modifie the engine case, because the 36 HP cylinder bore is 81 mm, but the 40 HP big bore 83 mm cylinder is 87 mm on the case side. Does anyone know, if there is enough place beside the original studs? I don't want to modifie them. Thanks for your help!!
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Kjell Roar
Samba Member
Joined: December 08, 2008
Posts: 1326
Location: Norway
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| Posted: Fri Nov 04, 2016 3:09 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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I have checked the possibility to do that with a Mahle big bore set I have. You have to modify the cylinder walls where the sylinder studs are, because of thighter spacing. And cut down the finns at the top, because the 40hp cylinders are wider.
It has been done by others.
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Last edited by Kjell Roar on Sat Nov 05, 2016 12:25 am; edited 1 time in total |
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akomjathy
Samba Member
Joined: October 15, 2004
Posts: 208
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| Posted: Fri Nov 04, 2016 3:12 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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| Kjell Roar wrote: |
I have checked the possibility to do that with a set of Mahle big bore set I have. You have to modify the cylinder walls where the sylinder studs are, because of thighter spacing. And cut down the finns at the top, because the 40hp cylinders are wider.
It has been done by others. |
That's what I thought. And do you know anything about the cylinder head side? I am going to use the Wolfsburg West Okrasa heads. Do I have to modifie the cylinder wall, too? Thanks: Attila |
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pig-pen
Samba Member
Joined: December 04, 2012
Posts: 570
Location: United Kingdom
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| Posted: Fri Nov 04, 2016 5:31 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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without question you are going to have to machine everything.
there are a couple of threads re WW okrasa heads, and the extra size actually benefitting the seal between head and cylinder...
machine heads.
machine fins.
machine case.
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Kjell Roar
Samba Member
Joined: December 08, 2008
Posts: 1326
Location: Norway
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| Posted: Sat Nov 05, 2016 12:29 am Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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It is at least one thread showing what to cut down, here on thesamba. Search and find 🙂
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AirCooledClassics
Samba Member
Joined: August 20, 2004
Posts: 294
Location: Saskatoon, Sk Canada
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| Posted: Sat Nov 05, 2016 10:26 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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Mathews pics were very helpful to me. I.ve done this mod several times. It is very time consuming . The heads and case need to be opened up. On the case you cannot use a flycutter.It must be milled, Or get a flycutter made in about 1967. I install case savers and used 8mm studs to make the cutting easier. many other just use an angle grinder to clearance the barrels for the stud. If you have access to a mill check Blacklines build on their 36 hp challenge its much nicer than the way I do it. I hear that AA is finaly doing the 80mm big bore kit. With no machining that's the way I would recommend .It has an easy button.
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earthquake
Samba Member
Joined: January 10, 2008
Posts: 3984
Location: SANDY VALLEY, NEVADA
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| Posted: Sun Nov 06, 2016 6:22 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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How about offsetting case savers in the case and using 8mm studs? that would give you a bit more room.
Casey
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Mr. Okrasa 
Original Old Speed
Joined: May 20, 2000
Posts: 726
Location: Eastside, Costa Mesa. So. Califas...Loco's ;-)
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| Posted: Sun Oct 01, 2017 11:26 pm Post subject: Re: 36 HP engine case with a 40 HP big bore 83 mm p/c kit |
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It would be easier to use 912 cylinders, bore 'em 1mm and install 40hp pistons. You would trim the bottoms and tops & remove 1 fin.
You would not need to trim as much fins to fit under sheet metal. Worked for me. 
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