Build Project: Wilbur’s 2.1 DJ

For documenting and technical details of T25 restorations and major repairs
This section is for major restorations only.where to buy a panel or where to buy window rubbers belong in the bodywork seats and glass section.
Also please note,we need pictures of the restorations,without them posts are pretty useless.[\b]
Picture heavy and detailed threads , not for general banter or advertising
Traders welcome to post but not to advertise blatently
Threads will be cleaned of chit chat.

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DoubleOSeven
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

1200 grade wet & dry on barrel sealing surfaces. Before (L) & After (R)

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Last edited by DoubleOSeven on 03 Apr 2020, 19:45, edited 1 time in total.
1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

These are not budging so I’m going to leave them alone.
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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

I did get the fire rings off eventually.
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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Cleaned and Ready
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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Pulled the pistons. I use a flanged M8 nut for the gudgeon pins.
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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

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 all weigh 452g

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

That’s it for today.

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Oh and I’m done with cleaning, i.e. lost interest! This will do.

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Oh cleared all the gunk out of here, but can’t remember what this hole is for, off hand.

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Some numbers, 93.991mm

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Rich @ Crazyquiff’s (Mk1 Golf specialist) welded a engine case for me, way back when, so I know he has a welder with sufficient power to repair the crack.
So much heat gets dissipated through the case, so it takes some doing.
1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Talking of Mk1’s; I enjoyed my Mk1 Campaign, we made the front cover of Practical Classics and attended a photo shoot. Pub quiz knowledge; Campaigns had green tinted windows, which I always thought was a nice extra.

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Re: Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Anyone got a url for Hymolar AF?
1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Head No.2 has issues. Need a machine shop for these broken studs ideally.

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...and the barrels need honing. I don’t have that tool.

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Cleaned up ok though,fire rings and valves are out.

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Last edited by DoubleOSeven on 04 Apr 2020, 13:36, edited 1 time in total.
1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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DoubleOSeven
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Posts: 2483
Joined: 25 Jul 2014, 21:10
80-90 Mem No: 14520
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Build Project: Wilbur’s 2.1 DJ

Post by DoubleOSeven »

Pushrod tubes can be used again. Bench mounted wire wheel used.

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1990 Volkswagen Transporter 2.1 Manual
2005 Porsche 911 3.6 Manual
2012 Volkswagen Polo 1.4 Automatic

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