Jeff's Bus Stocker Plus

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This just in…

Big thanks to our man ‘txoval’ for another generous donation!

All we need is Jeff to get that case cleaned up,
And we can start some mock-up.

Clean, Jeff, clean!!

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Bus Motor Build

What’s That Noise?!?

[txoval]

I have a CB welded 37mm wide fan too if that would help

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This also in..
Packed like precious china..
A pair of dirty dawgs!

Complete,
Throttle shafts feel decent,
Vacuum port,
What a score!

Big big thanks my man.

We already got a Scat linkage ordered,
Plus we'll do the cleaner mount raise trick.
These puppies are going to be given every chance.

Jeff and his ultrasonic will be busy for the next couple of days,
Plus, we'll load some soda in the cabinet.
Oh, it's gonna be a party..
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Bus Motor Build

What’s That Noise?!?

[VWporscheGT3]

isnt the VW community awesome... just amazing
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Schnell, SCHNELL!

I like being wrong, Because, it is another opportunity to learn. If you stop learning from your mistakes than what is the point?

If you have any questions about Forged ICON 4032 VW pistons just shoot me a line.

[txoval]

In a bus I’d imagine he’ll be running at high (relatively speaking) rpms a lot with reduction boxes…the welded fan is good insurance.

No problem sending it…

[Seasurfnbird]

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[txoval]

I tore my ACL playing soccer on Sunday...so give me until next week and I'll send it.

Same address?

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Man, I'm stoked about how this is coming along..!
That welded/balanced fan would be such a swEEt touch for this one..

Jeff came by yesterday..

We got his Grant rings checked out.
.017 or so end-gap out of the box.
Not super ideal, but better than the .022 max listed in the bible for new (smaller cast 85.5) rings.
Cylinder-to-skirt is right around .0036 - .004 depending upon where you measure it.
We gave his cylinders a 240/600 plateau dingle-ball job so the bit bigger numbers are to be expected.
A hot-running Bus, and these numbers are OK.
Besides, what can you do about them now?

We also cleaned up his factory 1.1 rockers and got the solid shafts/swivel feet ready to go for when the heads get back.

He's also getting the case vapor-blasted, at least the front section that shows when you open the decklid..

Jeff just sent me this pic - Scat linkage is in.

Anybody know where to get a pulse valve for the vacuum advance?
Now that aircooled.net is on hiatus,
I have NO idea where to get one of those.
It made such a difference on my Beetle motor with Kadrons..

Jeff has the K Dogs at his house,
And he has an ultrasonic.

Now all he needs is to get to work!

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Bus Motor Build

What’s That Noise?!?

[jimmyhoffa]

QUICK! GET EM!

There's only two left-
https://www.ebay.com/itm/372035338115?chn=ps&n...8OEALw_wcB
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1974 Chenowth 2RL #1244 Street Legal
My other car isn't ridiculous.

[Clatter]

Nice! Thanks for the tip.
Jeff got two of 'em (he has a Squareback that can use the other).

He also got to work.

He's mostly-disassembling them one at a time, for ultrasonicing.
So's not to mix anything up or lose track of how things go.
He was taught to use carb dip in his ultrasonic.
Now that carb dip is EPA-compliant and sucks, I guess that's a good use for it.

Nextime he's down we'll soda-blast the bigger parts and go thru everything.
Unfortunately, I've been thru Kadrons so many times i can do it blindfolded now.
Making our shopping list for Kaddie Shack; goal is to do it all in one shot.
We'll do the air filter mount raise spacer deal, and probably new cleaners, plus kits and maybe jets.
The manifolds will get matched to heads, the balance tubes plugged, and the Alstrup divider wall lowering and bowl open up tricks.


Jeff's crappy case had two coats of old paint (partly) on it.
It was terrible looking, and i can't help but think paint insulates cases from shedding heat.
Been blasting cases lately with good results, but only provided the galley plugs are all out,
and some real diligence is employed in their cleaning afterwards.
A local MC shop does vapor blasting, and quoted Jeff $300 to do the job completely.
They will, however, do a $100 job if you ask them to.
We tried to have them hit the parts of the case that actually show,
But,
Here's what you get for $100.
Looks way better than it did.
$300 is more than this case is worth...

Man, cases are a real issue these days for those of us who aren't independently wealthy.
I remember finding a pile of single relief cases needing their first line bore in a field for free..
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Bus Motor Build

What’s That Noise?!?

[txoval]

I’d hit it with a light coat of cast alum or cast iron paint…I’ve never seen a drawback to it, but understand it is a debated item

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Spent some time looking at cases..

Using drill bits as gauge pins to check oil gallery sizes,
There are indeed differences between single and dual relief.

The actual bearing feed holes are the same size,
However,
There are differences in the main feed galleries,
Just like Torben says.
These bits all fit into a late case, but not early:

Here a later case has a similar size small feed hole for the cooler,
But unlike an earlier case, the outlet is larger:

Dag,
It's not a huge difference.
The oil pickup tube is going to stay small.
The bearing feed passages are the same size.
If you look closely at the long main passage where the full-flow returns to the case,
The dual-relief case seems to have the casting thicker around that gallery.

Still,
The factory didn't usually just change things for the fun of it.
Their changes to things like this were typically an improvement.

Not a big deal to go get some bits and take these over,
but,
Man!
The risk of ruining the case looms large!
And,
Are we _sure_ there's real gains for a mild 1776?

Hard for me to pull the trigger on this one, gentlemen.
Maybe if it was my case..
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Bus Motor Build

What’s That Noise?!?

[txoval]

Wish I had one to send you…

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[Alstrup]

Definitely enlarge the galley!!!!!!!!
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https://www.thesamba.com/vw/forum/viewtopic.php?t=435993

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So Jeff was here all day yesterday doing not-fun stuff...

Loaded up soda in my blasting cabinet, but it sits outside and it's been wet.
Have to bang the thing while trying to blast otherwise it doesn't feed.
No light or fan inside either (it's on my list ).

A long frustrating session but he did a great job.

It was cold and wet and windy.
One thing i learned as a young teenage apprentice mechanic is how to heckle.
When a newb gets frustrated the old-timer has to needle.
Things like:
"Aawww.. she's getting upset.."
"Want a cookie?"
"You should buy one of those 11-thousand-dollar blasting cabinets with the vibratory feed"
"Want me to just do it?"

It's also always important to use the word "Buttercup" as much as possible.


The process of cleaning out a case that's been wet-blasted is a fun one.
First dry air blow-out,
then carb cleaner and more blow-out.
Gunk and high-pressure water, more air, more carb cleaner, more air.
We're clean enough for some mock up, and it was dark outside by then.
Final clean will be the dishwasher once all mock-ups are done.

PO used silicone everywhere.
Best of all, they decided to pack the pushrod tube/lifter area with tons of it.
By the time it was all scraped out, we decided to smooth up the seal area with a tiny wire wheel.

Mock-up all tired and cold and smelly was no fun because the crank decided to bind in the bearings.
It spun free before. Not sure how cleaning a case suddenly causes it to change shape.
That, and every head stud was -removed by pliers on the threads- by the PO! :snipersmile:
After smoothing down the bearing dowels that were somehow all chewed up.
It started to spin better.
The bearings are likely -slightly- out of shape now,
but I'm 100% sure they'll round right back out once that motor hits 5500RPM.

Anyhow,
One bright bit was the fact that the deck measured right at .030.
This means it won't have to go back to Jim for another decking and he won't hate me for making him do re-work!

So, we're finally getting close to actually bolting something together.
And,
If I'm not mistaken,
We're done cleaning stuff!
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Bus Motor Build

What’s That Noise?!?