Build Project: Wilbur’s 2.1 DJ

Post by **ajsimmo** » 04 Apr 2020, 13:23

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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Post by **ajsimmo** » 04 Apr 2020, 13:28

Just to show I didn't cheat!

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Post by **DoubleOSeven** » 04 Apr 2020, 13:38

Ah, good stuff. Thank you.

Post by **DoubleOSeven** » 04 Apr 2020, 13:43

Post by **ajsimmo** » 04 Apr 2020, 13:58

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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Post by **DoubleOSeven** » 04 Apr 2020, 14:11

Dishwasher had a go at head #2

Post by **DoubleOSeven** » 04 Apr 2020, 14:17

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

Post by **ajsimmo** » 04 Apr 2020, 15:09

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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Post by **DoubleOSeven** » 04 Apr 2020, 16:19

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...

Post by **DoubleOSeven** » 05 Apr 2020, 12:41

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.

Post by **DoubleOSeven** » 13 Apr 2020, 09:28

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.

Post by **DoubleOSeven** » 13 Apr 2020, 12:45

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

Always nice, when the VAG emblem appears.

Post by **DoubleOSeven** » 19 Apr 2020, 13:28

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.

Post by **Wilber** » 21 Apr 2020, 06:54

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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Post by **DoubleOSeven** » 22 Apr 2020, 00:00

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