Build Project: Wilbur’s 2.1 DJ

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ajsimmo
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Re: Build Project: Wilbur’s 2.1 DJ

Post by ajsimmo »

DoubleOSeven wrote:These cheapo verniers are no use here, there is no way these pistons are 0,5mm under spec. @ 93.4mm Barrels all measure 94mm.
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Pistons are wider below the rings, and should be measured near the bottom. My cheapies seem to be bang on.


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Re: Build Project: Wilbur’s 2.1 DJ

Post by ajsimmo »

Just to show I didn't cheat! :-)Image

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Ah, good stuff. Thank you.
1984 Caravelle 2.1 MV

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Re: Build Project: Wilbur’s 2.1 DJ

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Re: Build Project: Wilbur’s 2.1 DJ

Post by ajsimmo »

Those broken studs in the head. Do you have a tap & die set? If so just drill them out and clean up the threads. If you knacker the original thread (or it's already knackered), Heritage do a very useful step-down M10/M8 rescue stud.
https://www.heritagepartscentre.com/uk/ ... m8x38.html" onclick="window.open(this.href);return false;Image

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Dishwasher had a go at head #2

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

I do have a tap and die set but I don’t have a pillar drill, so keeping it straight is my worry.
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Re: Build Project: Wilbur’s 2.1 DJ

Post by ajsimmo »

It's fairly easy with a hand drill by eye, and not super precision critical. Get a helper to "Golden Shot" you!
(For the whippersnappers here, "up a bit, left a bit, down a bit etc")

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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Had a crack at it...still at the 6.3mm drill stage

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M8 x 1.25 TAP = 6.9mm drill bit

M10 x 1.25 TAP = 8.9mm drill bit

(Do I have these sizes; No)

Still, fairly productive day. I’ll keep going...
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Lapped the valves in head No.2, took the fuel pump blank off and cleaned the oil pressure senders, blue & grey. Need new piston rings from Will now and a clutch check before re-assembly.

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

There is some surface rust on the inside of the barrels, so I’m trying some Electrolysis on them.

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+12V 1.5A to anode. Barrels to cathode.

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Few tablespoons of sodium carbonate in tap water.
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Zero rust, in what - a couple of hours. Still need honing, mind.

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Always nice, when the VAG emblem appears.

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Sometimes it’s best to walk away from something and come back to it later. Jumped on the x2 M8 threads today which required a drill & tap. Got them completed in 10 mins. Heads are ready now.

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Re: Build Project: Wilbur’s 2.1 DJ

Post by Wilber »

Doing a cracking job, honing tool will be with you this morning a piston rings are on order and should with you this week. Keep sane!


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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

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