Pushrods/valves SEEM dead / engine build

[Rickf1985]

I realize this is all past history but look very closely at the case where that cam gear runs very close to it and see if you see any witness marks where the gear may have jammed something into the bottom of the case. There may have been a loose nut or small piece of metal floating around in there for years that finally found it way over to that gear where there is no clearance between gear and case.

[NachoCar]

yeah I would LOVE to know what the root cause was. I'll inspect for marks for sure!

Had one smarty pants engine builder who said it had to be the distributer drive shims/washers (he was twice the price of others like chico, mofoco, and strickly foreign). There were 2 still on and no remnants from any others

A mechanic I trust thinks the cam gear itself was defective.

It would be nice not to have a repeat, if you know what I mean.

[Rickf1985]

Well, The reason I mention this is I have seen that happen once before. BUT, I was after the #2 rod decided to become a multi piece rod at about 7,000 rpm. As the engine was still winding down in gear then bits and pieces got caught under that gear and did exactly what you see there. So, A little different set of circumstances but same end result.

[Buggeee]

I love that you are building this yourself. You will succeed. You will feel like a million dollars. This is the best part of this hobby.

P.S. I just peeped your gallary... that is a bitchin' grasshopper Dude!!!
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[NachoCar]

must be searching using wrong terms. Need quick advice.


Need to install a main bolt, one of six bigguns used to bolt case halfs together.

Finger tight with Permatex aviation? Guessing it will snug up when torqued properly?

Thanks I LOVE this shit.....and not too much to lose at this point.

[scrivyscriv]

Don't use any kind of sealant on the case stud where it threads into the case.. You'd do just fine to use red or blue loctite. I have always set most studs very snug past hand tight, but that may just be personal preference.

I think you will get it back together and be happy with it.. Tearing down and repairing an engine, and putting some miles on it after, is very rewarding.
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[Buggeee]

I agree, you just want the stud to stay In place for the assembly so it does not get any torque at this point because you don't want to punch it through or crack anything. I use blue loctite putting a stud in a case or head because it can be dissasembled, whereas red loctite is permanent. I use red loctite on a Timesert when repairing a hole.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[NachoCar]

Thanks guys.....I had already used blue loctite and made it flush with the other 2 bolts on that side. Fingers crossed!

[NachoCar]

[goober]

[Rickf1985]

And there you go. You will probably never know what it was but from looking it was not very big nor does it look like it was sharp sided steel. It may be just what the machinist said and it could have been a defective gear and that was a piece of it that came off and jammed. I have never seen one of those gears fail just on their own but there is always a first. And probably many more that were never reported, like before the internet. Back then they saw that and tossed the whole engine in the bin and pulled another out of another of the hundreds of cars in the yards.

[vamram]

Nacho Car, what is it you found? Blame my ignorance but I don't see the smoking gun...?

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Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
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[NachoCar]

[Rickf1985]

He is talking about the gouge in the oil galley between the cam bearing and he oil pump where the gear jammed something between the gear and the housing.

[vamram]

Ah ok - now I see it. Thanks.
_________________
Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[NachoCar]

couldn't get the main bearings orientated and seated correctly.

Ruined a set of German bearings and smooshed a dowel into the case. Hope there is enough left to hold bearing in place.

Off to research tips on marking and placing bearings correctly. dang it.

[Buggeee]

There is a learning curve for sure and when done with the build will be ready to begin.

So the assembly should rotate smoothly when torqued down. Along the way, rotating the assembly periodically as things are getting tightened can sometimes disclose things like this before fully torqued down. This is a common experience.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Rickf1985]

Patience my friend, Patience is key to building an engine. as you are putting the bearings in you can move them around just a bit and you will feel the dowel key into the hole. I am guessing you had the bearing in backwards and the hole was on the other side of the bearing? Especially since you are just beginning you need to take your time, have the manual open and check everything several times as you put it together. If you are watching a instructional video of engine assembly then do not be afraid to pause it, back up and look again. whatever it takes but patience. Do NOT try to keep up with the video. If you get frustrated then walk away, shut the lights off and come back later. Even shut down for the night and take the video inside and watch it over a couple of times.
Even those of us that have done hundreds of engines and make it look so easy and quick, we are still doing all the things I am telling you like feeling for the dowels, felling for tightness. Making sure all surfaces are spotlessly clean. It looks like we are not doing it since we move faster but we do all of those things. It becomes routine. Do not try to emulate the guys on the videos, they have done this so many times it is all habit to them and you do not see half of what they are doing because it is mostly in their heads.
And, above all, if you get stuck, DO NOT GUESS! Come here and ask before moving on!

[NachoCar]

Thanks for the wise words guys!

I do tend to rush a bit.

[vamram]

I've assembled two engines and did this exact thing with the 2nd one. I knew immediately something was off because I couldn't turn the crank once I reached the final torque on the case bolts. Fortunately didn't damage the case and discovered it before final assembly and break -in.
_________________
Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!