WW Okrasa manifolds and carb issues

[fl59bug]

I just received my WW Okrasa kit yesterday, and was excited until I had a look in the manifolds and one of the carbs.

I see a fair amount of rust, welding flash, cold welds and wire ends sticking out. There would be a major issue if these were to break off and go down in the engine, and at the very least horsepower would be robbed due to the fuel mixture having a less than smooth path to travel. See pictures below.

Also on one of the PCIB carbs there is what looks like either a scoring mark or a crack where the throttle shaft meets the carb.

Has anyone else seen these issues with their Okrasa kits? Fyi I emailed WW this morning and haven't received a response. I also called them, and was told someone would call me back, but nothing yet.

[fl59bug]

Wouldn't you know it, as soon as I posted this, they emailed me back. In fairness to WW I'm posting up the reply:

Hello



Thank you for the photos.



The manifolds we offer are consistent with the photos you’ve sent. Original manifolds had the same issues.



Regarding the carburetor, I believe the line is from machining. If you have any problems with it, please let us know, and we’ll be glad to inspect and replace if needed.


Feel free to email with any further questions.



Thank you.
Sean

[[email protected]]

[Braukuche]

That's pretty nasty looking in there and that response is lame. So they did a shitty job 60 years ago, so that excuses doing a shitty job today?
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[TRS63]

[fl59bug]

I agree - weak response and shoddy welding!

I bought an extra long extension and grinding stone and I'm going to try and smooth out this mess a little at least.

[JeeWee]

they all have this issue, therefore you need to grind it with a dremel or a similar tool. While working on the manifolds, please place a gasket on the cylinder head side and match port that side, because it is way of and restricting airflow ALOT!

also check the exhaust ports, easily to put a gasket over the studs and check if the port is centered, as mine were off.

also removed some minor burrs in the inlet port of the heads.

I was not impressed by the quality of the WW kit I threw away the manifolds and carbs and converted it to zenith 38NDIX. After 7.000 miles also replaced the valves in the heads. Also had issues with the head, the well known blow by between cylinder and head, so went for the 80mm bore AA PC to finally solve it.
So in the end it would have been the best is to buy empty heads, bore it to 83mm, choose your own valves (BE Ferrea) and some nice carbs...

even if your carbs are reworked, check and remove the carb as well for burrs, this to optimize the inlet air flow.

all the small bits help to get a nice output and smooth running engine.

and make sure the jetting is right for YOUR engine!
_________________
1192CC WW okrasa
48,2 DIN PS (58SAE HP)@4430rpm - 83Nm@3610rpm

[fl59bug]

Thanks. I see in your sig you are still at 1192cc, but with 80s aren't you at 1286cc or so?

I like what you have done with your engine. I will definitely try and match the manifold to head and exhaust outlets to the gaskets.

I am working on grinding out the junk from these manifolds, and I bought an extra-long extension and grinding stone for my drill to help with that.

[[email protected]]

[TomSimon]

Those 'flaps' of steel would not treat the engine nicely if one broke loose.

Pick up an air or electric die grinder, Harbor Freight quality will do, they come with a 1/4" collet to accept 1/4" shank carbide burrs and cartridge sanding rolls

https://www.eastwood.com/1-4in-shaft-double-cut-6in-burr.html

https://www.eastwood.com/engine-porting-kit.html

Then go to town cleaning up the inside of the manifolds.
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[fl59bug]

[fl59bug]

[Mr. Okrasa]

Send me your carbs. I install the correct jets, rebush throttle shafts and install the correct venturi. Have you seen my ads that offer this service?
Nothing more frustrating than trying to set-up your carbs and nothing is working....
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Denzel engine running. See this link: https://youtu.be/DgUlsQDTXTE

VW www.Okrasa.com
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[fl59bug]

[slalombuggy]

All you need is the 4 piece bit set and the porting kit, the other bits are just extra. You could probably just get away with one bit and the porting kit, but the other shaped bits are nice, I use my ball bit a lot.

brad

[fl59bug]

Looking to get the 4 pc and porting kit shortly. Gotta let the wallet recover after going on a spending spree lol.

Looks like the manifolds don't just slide right over the studs on the heads either and will need some finessing. I tried to double nut the head-manifold studs out, fit the manifold then screw the remaining studs back in but the holes in the manifolds will need to be wallowed out a little, in particular the inner of the 3 studs. So that is on the to-do list as well. I do know that this fitment work is "normal" and so I'm not whining about it just mentioning to hopefully let others thinking about purchasing the kit know what needs to be done.

I did ensure the carbs and air cleaners go together and bolt onto the manifolds and that looks to be no problem.

[JeeWee]

[wheel607]

Why doesnt Wolfsburg West (Tony) price these like it is 60 years ago since he states that the (lack of quality) is the same as it was. What a poor excuse for BAD WORK. He charges a lot for this kit and the quality should reflect the price. It would be easy to clean this up before he ships them out. This is not the Wolfsburg West of old. Sorry to respond to an old thread, but I just saw it.

[earthquake]

If those were my manifolds I would cut them apart and clean them up and TIG them back together.

eQ
_________________
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[fl59bug]

Yeah I hope the driving experience makes up for the many shortcomings of the kit itself. It is somewhat frustrating that WW charges so much for a sub-par workmanship on the manifolds.

Between having to clean up the nasty mess in the manifolds (done sometime ago) and the rocker shaft bosses cracking down the middle when I tried to shim them, I'm ready to move on to another project that is more rewarding, like my 2332 which I'm waiting for another engine stand for.

I've got to put in an order here shortly for the replacement heads and I'll use those with the 2 pc AA lifters, their chromo PRs and adjustable PR I bought to get the rocker geometry right, and then I hope I can finally get this thing running, tested and installed.