Club 80-90 Forums

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.

Pistons are wider below the rings, and should be measured near the bottom. My cheapies seem to be bang on.


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Just to show I didn't cheat!

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Ah, good stuff. Thank you.

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;

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Dishwasher had a go at head #2

I do have a tap and die set but I don’t have a pillar drill, so keeping it straight is my worry.

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



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...

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.

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



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



Few tablespoons of sodium carbonate in tap water.

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







Always nice, when the VAG emblem appears.

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.

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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