Aidan's wbx 2.5

[silverbullet]

I'm starting the new year with a rapid 2.5 build for our very own gearbox guru.
The case was prepared for 98mm cylinders a while ago and I'm going straight to it from the recent early DG to DJ conversion job.
The big change is the use of aftermarket SCAT 5.4" (137mm) conrods because I have changed the piston spec to use 22mm pins, as opposed to previous builds which used reworked original wbx rods with 24mm pins.
This was a deliberate move, the US market has been asking for this change for a while and the payoff will be a smoother and less stressed engine for the following reason: the SCAT rods weigh 575g vs the OEM ones at some 645g.
The 98mm pistons are also significantly lighter than the original DJ parts (I have published the figures previously) and this all means less reciprocating mass, meaning reduce loads on the big end bearings and a smoother running engine.
Another benefit for me is that the case will require less clearancing!

Its getting a pair of low-miles AMC heads too, usual drill there: reamed exhaust guides, lightly ported, 30degree back-cut on the valves etc.

[ash1293]

You do know how to tease..... I’m under strict instructions that I’m not allowed to enquire “how much” while I have no running issues..... maybe that’s tempting fate.

[rollercoaster]

As the saying goes, “if you have to ask..”
But no worries because you dont have to ask..
So you should be able to afford it!

Aidan, I do hope this is for your own van,
Wishing you well with it.
Tell us more how it’s coming together..

[ash1293]

It’s more the if it ain’t broke mentality here. Long term it’s an option if it needs it, while Subaru is tempting there’s something very attractive about keeping it a VW WBX

[silverbullet]

A day of repeated dry assembly tests and a lot of compressed air later, the rotating assembly and pistons clear the case and it turns cleanly.
The SCAT rods require less work doing to the case, but I didnt want to remove more metal than necessary.


I now have a Wanted out for dual thrust cam bearings so that I can get the cam timed, they seem to be in short supply or £££

[silverbullet]

Dialling in the cam timing this evening

I use an extended cam follower to find max lift

[silverbullet]

That's the worst of it done.
Ring gaps checked, triple O-ring port matched 26mm oil pump, heads are prepared and cleaned up nicely

Just need to clean some pushrod tubes and it will be pretty well built.

Apart from the usual faff of shimming the flywheel

[silverbullet]

Almost forgot: the sump plug had previously been fitted with a M14 x1.5 Time-sert (badly installed off-axis) and had a two-angled seating that would never have sealed.
The only option was to machine it out, cut a new seating and fit a M16x1.5 Heli-coil.
I then opened up the recess a little to allow plenty of space for a 17mm socket to fit the plug.

[silverbullet]

Now that the ultrasonic machine is useable, the first test was a set of pushrod tubes for this build. Even after an initial external scrub and wash in brake cleaner, the muck that comes out of them after a few minutes is alarming, but satisfying to see. Definitely the cleanest I have ever fitted after NOS sets but why bin perfectly good parts?
Anyway, now it looks like a long motor

A selection of external pipework has gone off for plating along with other parts, so should be back in a few days, unless Aidan wants stainless of course.
Just the flywheel left to shim and a good triple pulley required.

[ash1293]

..... and Aidan new delivery address is..... my house, my street, my town.


Looking great, sounds like the ultra sonic tank is going to be one of those better accidental buys. Think it will get a lot more use than maybe originally thought?

[silverbullet]

Well, if the wbx enquiries pick up its going to pay for itself sooner rather than later!
A £50 cleaning charge at my local engine shop actually cost me more like £200 in lost shop time due to driving there and back twice, so its already a winner.

[Deberius]

Great Job

One question: Which head casket rings did you use, or did you machined them?

[silverbullet]

I get the rings made for me, cut by water jet from copper sheet.

[silverbullet]

It always slows down at the end (also been very busy)
Flywheel recovered, not easy when they get a bit "wiped" as the metal gets hardened but at least it is flat and has the correct clamp height: 24.75mm for reference.
I turned 0.5mm off in the end.

Need to get this one shimmed and off the stand, there's a 2.1 DG upgrade now waiting in the wings!