Hey peeps,

Time for an update, quiet week on the van front busy week at work saw to that. Today was a good day for it though.

The plan was to mock build the motor today to enable measurement of deck height, however I started building the crank up and found that the rods were tight on the journals!
It looks like I will need to take them for Honeing. Also need to clearance the back of the oil pump as it's fouling the cam bolts.









Since there I couldn't go any further I finished off the combustion chambers.



Next match porting the manifolds.







Both manifolds sorted, them moved on to lapping the valves in.





That's it for this weekend, need to drop the crank and rods at the machine shop Monday to get that sorted, then it's full steam ahead.
Cheers for stopping by.

Happy Sunday guys!

Good day on the bus yesterday, started out finishing off the cylinder heads valves all lapped and installed.



Also assembled the throttle bodies. Cleaned up following match porting, installed injectors and fittings.





Conrods and crank dropped at South Cerny Engineering for rod re-sizing so that's it for engine building this week.

Continued with primer two more coats on the underside ans in ther cab area.









More later today hopefully.

Well I got 3 hrs in this evening, got the DA fired up and said good bye to more of the Pink!









With the majority off I will now wet flat the top to remove the rest of the beige.

Saturday is Split day! So 8am start this morning continued with the paint prep on the right side.

180grit on the DA and a light run over to take the top layer of beige under coat off the blue. Also paint stripped some nastys off the front wheel arch which caused some reaction when primed.



Then cleaned off the long side and keyed it with 150 on the DA also cleaned up the rear vents and arch which had some light surface rust.





Panel wiped then masked up.



Mixed up a gun full of Octoral wash primer and primed the side and arch.





Seam sealed the panel with bond and seal and left that to cure.



Before I knew it 6pm was upon me! Until next time!

Bit of week day bus tinkering this evening!

Collected my crank and rods from the engineers. Got cracking with assembly after work.







Dropped the crank into the case.







Barrels and pistons tomorrow.

Evening all,

Had a busy end to the week. Got barrel and and piston installed on the motor to enable a deck measurement. I have 1mm protrusion so I need to shim the barrel currently I'm researching my compression ratio. To determine the shim size and copper gasket thickness.









At present with a .060 deck height my compression is 11.0:1 so I will need to increase the chamber size from 42cc to 52cc then with a deck of .090 will give me 8.7:1 I may even try to increase the chamber more so I can tighten the deck height, this will reduce the risk of detonation.
I've started to look at where I can take material from I'm hoping up shrouding ther valves will do most of the 10cc I need to gain.





Today more body work, the cargo doors were on the agenda. Once removed from the shell I then realised that I had no yet spot welded the lower edges of the repair skin.
So out came the welder!





Once all welded up I cleaned it up and then got busy with the sander to take off the multiple layers of flakey hand brushed paint and silicone sealer.







Ready for etch and high build!

Great work! Loving this build thread.

You will soon find out that 10cc is a LOT. Dishing 94mm pistons can give you up to 7cc, hopefully the rest you can find in the chamber.

Excellent work all around! Where did you get the manifolds?

GTV wrote:You will soon find out that 10cc is a LOT. Dishing 94mm pistons can give you up to 7cc, hopefully the rest you can find in the chamber.

Excellent work all around! Where did you get the manifolds?

Yeah I realise 10cc is a massive amount, the heads spec at 52cc but I've measured them a number of times and they are Deffo 42cc, currently looking at redesigning the chamber to see what I can gain.

I was trying to avoid piston machining to keep plenty of crown material.

Manifolds/throttle bodies are part of the fuel injection turbo set up from VW Speedshop.

Amazing progress whilst Ive been away mate. The van is looking really good for all the hard work, and coming along nicely. As for that motor though, I love it!

What comp you aiming for with it as you say you are researching it I expect you arent set yet? With turbo motors I believe 7.5 to 8 is the sweet spot, but depends on boost etc? Will you be using an Intercooler and Water/Methanol or running lower boost to save the hassle?

It's been a productive week, I was in the Brighton area earlier this week so stopped by VW Heritage and picked up my Barrel spacers and copper head gaskets. Just need to rework the chambers now.

The list of jobs grows by the day on the shell, as I work round with the prep and primer. Yet more welding to do!

Had a good couple of days on the Bus this weekend, Saturday I prepped the left side panel, the roof repair and rear corner for etch, degreased keyed and masked up, also etched the inside of the cargo doors.















Today first thing I seam sealed the side panel, c-pillar and sill. Then carried on with the prep of the engine shelf, had to weld a few screw holes that I missed!
As I was going to fill the paint gun I flipped the cargo doors over and wiped them down ready for some primer.









Whilst that was drying I took the tailgate, engine lid and valence up to work and jet washed the inside to get all the oily residue off.



The tailgate needs the seal lip repairing in two places and the engine lid needs some welding at the hinges and behind the number plate light. So best get on with that this week.

Lastly today I made a start cleaning the peak up, it was quite crusty so took it back to bare metal and tarted with some rust converter.





Lots to do this week! Never ending restoration!

wejjy wrote:Amazing progress whilst Ive been away mate. The van is looking really good for all the hard work, and coming along nicely. As for that motor though, I love it!

What comp you aiming for with it as you say you are researching it I expect you arent set yet? With turbo motors I believe 7.5 to 8 is the sweet spot, but depends on boost etc? Will you be using an Intercooler and Water/Methanol or running lower boost to save the hassle?

Cheers mate, it does seem to taking forever to get anywhere at this point! There is just so much to do!

Compression ratio is going to be 8.5 :1 to keep It drive-able in the lower rpm range before boost comes in, I will be running a charge cooler from the outset and may add a water injection system at a later date. Only ever run NA air-cooled flat 4's so looking forward to running this one.

Had a couple of hours tonight so made a start on the engine lid repairs.

Hinges, no plate lamp and catch mounting.







Started straightening it all out.



Had to cut the strengthener open to get it right.





Job done all ready for welding!

Hour and a half in on the bus tonight, finished the engine lid repairs off. Also made a start on the tailgate.

Made a start on the tailgate repairs tonight, Made repair sections for the right hand side.









Getting there now!