Mike1973 wrote:So, time to remove the 30hp. It will get carefully stored as a spare motor. (And I may get the generator rewound to 12v, and fit a 12v 180mm flywheel.)

That would have to be a custom flywheel - machine the existing ring gear off a 30hp flywheel and press fit a new ring on. Heritage used to sell the rings, but don't seem to list them now

Paul, the flywheel I found at the bottom of the garden, and used to clearance the gearbox, was actually a 12v 180mm one ... We didn't realise until we went to swap over your 200mm clutch.

Sat morning, test fitting the partially stripped 1600 to check the flywheel clearence. Helpers Andy, Brian and Nige are doing all the work here!
We did the old trick of slowly tightening up the engine bolts, and turning the engien over to let the flywheel grind off any high points. Worked well. Although we didn't have a clutch fitted to it ...

Kombi upgrade in progress.

Engine back out and ready for assembly, so we could do a test fire up using the engine rig Nige had brought along. (Stupidly I have no photos of the test rig!)

1600 Engine Weekend


1600 Engine Weekend

We had a few issues starting the motor. What we thought was a dead battery was actually a dodgy earth connetion on the starter. After a few niggles were ironed out it fired right up and sounded great. Result!

So, next job was to get it back into the bus. Easy ... Not. With the clutch on this time it was a ball ache, even with 4 of us! We just struggled getting the shaft lined up properly without the heat exchangers being in the way. We got there eventually but it wasn't easy. Imagine our surprise then when not only wouldn't it fire up, it was locked up solid! We could turn the crank maybe 60 degrees before if locked up either way ...
After a little head scratching we figured it was the clutch that was fouling the gearbox. Engine back out again, and the bright spots on the gearbox confirmed the rivets on the clutch were hitting where the clutch throwout arm comes through. Arse!

It was a quick fix with the drill, but by now it was pretty late, so we called it a night and went inside to warm up with Susie's homemade stew and dumplings, and to sit around a log fire.

For those that can't remember the Kombi without them ...

Looks like fun. I would not mind some stew right about now..

Mike1973 wrote:Paul, the flywheel I found at the bottom of the garden, and used to clearance the gearbox, was actually a 12v 180mm one ... We didn't realise until we went to swap over your 200mm clutch.

.

Yes, but a 30hp crank is a smaller diameter, so it won't fit. The end play shims are totally different

paul_f wrote:

Mike1973 wrote:Paul, the flywheel I found at the bottom of the garden, and used to clearance the gearbox, was actually a 12v 180mm one ... We didn't realise until we went to swap over your 200mm clutch.

.

Yes, but a 30hp crank is a smaller diameter, so it won't fit. The end play shims are totally different

Of course! I had forgotten! Thanks Paul!

So, Sunday. We've hopefully made sure the clutch will take the flywheel and gearbox now! This time the engine went in much easier, we must be getting better ... We checked the engine was still turning freely though as we tightened up the nuts and bolts. All good, phew!
Started on the button. Why didn't I convert to 12v sooner? (Or rather, fix my 6v system years ago ... )


1600 Engine Weekend

Massive thanks again to Brian, Andy and Nige, for coming over and helping finally fit the thing! And to Susie for organising and cups of tea and grub! I wouldn't have done it without you! Thanks for helping me pull my finger out

Next on the list - Fitting the 1500 air filter ...

Thanks for Sharing Mike

great read and some nice pics to keep the combo alive


wave when you pass me on the motorway want you buddy


Mark

Great Write Up! You should be a magazine editor or something ;o) hahahahaha!

No more hand cranking then? Its a memory of Symonds Yat, a crowd around the hand crank handle - LOL

I swapped the crank nut over! Just need to butcher the rear tin a little ...
But the 30hp was easy to turn over, pretty low compression. I don't think the 1600 will be as easy!

I'm glad you will still be able to hand crank

I would love to have that option with Hector :):):)

Right, took the kombi on a proper run, after saying it ran a bit 'lumpy' on a tentative run around the block to pick Wilf up from scout Christmas camp Saturday. (in the rain)
Well, this time I made sure I got it warmed up properly. It was rough after start up, but soon cleared itself. Pulled away nicely. Going well, so took it for a quick blat on the motorway for a couple of junctions. Made no effort of getting up to speed, and cruised happily at 55. Noisy, but the engine temps were a steady 140. Pulled nicely up gradients too. Put me foot down and it soon got up to 60 but was noisy so backed off to 58ish, which it happily held without sounding like it was working too hard.
Off the motorway it died at junctions a couple of times. Restarted first turn of the key, so think that's just an idle adjustment. Took it up the steepest hill locally as well, which it climbed up in third easily.
Still a few small jobs to do, but the motor is running well! Chuffed to bits!
And as it was a night run, a good opportunity to test the headlights, which are a revelation after 6v ...
Thanks again to all those who helped XXX


Test Run by Mike, on Flickr

Lovely photo...

Seasons Greetings, and Best Wishes for 2016


Winter Service by Mike, on Flickr