Club 80-90 Forums

It sits where it should
"just" needs the bolt holes pitching round.

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All the holes line up. Thats a relief!

Waiting for some M7x1 cap screws to arrive (long story...)

In the meantime, there's a crank to clean and re-plug before being built up (Oettinger cranks are drilled differently to VW ones) and the case needs some windage detail work, mostly sharp corners dressing off.

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Crankshaft washing with brake cleaner. Hand brush, bottle brush, pipe cleaners, air line. Twice.
Then it got new aluminium blanking plugs fitted, staked in and it was time to check the front bearing orientation and fight with the cam drive gear...

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Cross drillings re-plugged and new rods torqued (with assembly grease on the bearings, of course)
The balancing grinding might look dramatic but it was checked and found to be spot on.

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www.aldonamethyst.co.uk

Vacuum load sensing system available for vac advance distributors (so it still looks right)

https://www.aldonauto.co.uk/ignition/al ... n-amethyst

After a delay due to a gear cutting "adjustment", blow me if I didn't guess at the cam gear position and the timing is spot on

Beginner’s luck!

You could not make it up! It was literally a case of "crank about there, so cam needs to be there-ish, looks somewhere near"
Found TDC on #1 and then wound it round to find peak lift. 112 degrees. Perfect.
I had to check it over and over, couldn't believe it.

A bit of good fortune is always welcome when developing one off specials. I can't to see this on the road.

There have been a lot of "thats going to be tight" moments on this project, both on the engine and the van.

A wet Sunday afternoon, I still didn't believe that the cam timing was correct. Went back to first principles, demounted the cam wheel, re-checked tdc.
Ended up on the same mark! Centre of full lift dwell at 112 ATDC.
So out with the screwlock, torque all the bolts and stake the last thread as for the full belt & braces.
Its done.
Next job: oil pickup and baffle mods...
 

Giving serious thought to moving the oil pickup to the middle of the sump and adding hinged "trapdoor" baffles to keep the oil returning to the central compartment at all times (the wbx6 has two pairs of cast-in transverse baffles as well as some bolted-in steel slosh plates)
Controlling oil surge is essential on steep climbs/descents and also under acceleration and braking.
Four trapdoors arrange in a square and some kind of horizontal baffle/windage plate would give some side-slope oil control too.

It’ll be 2 years, on the 12th August, for this thread. I’m getting old. Can you just put it together now please? I want to hear it running

It’s your engine. You’ll do what’s right. I find it best to sleep on decisions. The brain is a good problem solver when we’re not interrupting it, with our menial day to day activities.

I want it finished too! I lost a full 6 months waiting for the camshaft to be ground, then a problem with the cam drive gear (now resolved) both of which rather took the wind out of my sails, along with the tricky reworking of the inlet manifold and throttle linkage which did take a good bit of sleeping on.
All the pieces are there, this is the last internal detail before closing the case.
I have just gone back to genuine full-time work too...

DoubleOSeven wrote: ↑03 Aug 2020, 18:08 It’ll be 2 years, on the 12th August, for this thread. I’m getting old. Can you just put it together now please? I want to hear it running

It’s your engine. You’ll do what’s right. I find it best to sleep on decisions. The brain is a good problem solver when we’re not interrupting it, with our menial day to day activities.

Like you , would love to see and hear this, personally I always think that dog walks are the best time time to sort things in my mind