Club 80-90 Forums

george2490 wrote:More?

More.... are you sure....

OK, so here we go..

Now we can look at the crankcase studs..

These are helicoiled, and so have a tendency to wind out..clamp in place and remove the nut.. DO NOT..unscrew the stud.

I have a 'nut welded on stick' tool to check for stud tightness (make what you can of that Bobster )



Then clean every thread.. big studs..



and little studs..



and while we are at it..go over the cylinder heads..



If you are using new T1 / 2 chinese heads you will need to recover this little deflector :



I will come back to the heads later..for now we will start to overhaul the exhaust and heating system..

The heating system on a CT is probably the best set up of all the aircooleds.. with a dedicated turbine and 2 sets of exchangers..

But to work at it's best, the whole thing must be air tight..

so for example I'll use NOS for this one:



The front exchangers are the most exposed, but these have held up well,despite all those broken studs..



HERESY WARNING..

The druids say you can only use CT heat exchangers (at 245€ a pop), when with a discerning eyeball



you will see that a CT only heat exchanger is a T1/2 exchanger (at 121€) with a pipe welded on ..

Which said pipe has several holes where the clamp goes..



2 ways of doing this.. either spend 1/2 the day blowing holes in the rust with welding torch.. creating something grotesque..

and then having to grind it all off to get the exhaust to fit...

or:

Secure heat exchanger:



Then cut 35 mm of same diameter tube:



Which you then slice away 2x the wall thickness:



which is then soft malleted into place..with the gap in the insert lined up with the biggest rust hole..



Then welded and sanded to finish... the old exhaust clamp ring serves as a control on the pipe diameter to check for an easy fit..



I don't do struggle..

That's it for tonight..you may now resume a normal activity..

Cordialement,

Hello,

Well,

When I removed the valve spring on the 'dropped seat' valve..This is what we see:



The valve seat has dislodged and been driven into the head, the seat winkled out with no difficulty..

So I've been looking at a few cylinder heads

T2 (what I call deep head) and here CT (shallow head):




with the corresponding difference in number of cooling fins:
T2:



CT:



and going into my CT stock:



I've chosen a pair of late CT heads (9 mm valve stem 32 mm inlet), as opposed to early (8mm 30 mm), which will need studs and valve guides.
so off come the valves:



For the valve guides I use this 70's US kit:



Simple as shooting fish in a barrel..

Step 1) tap 3/8 thread into valve guide:



Step 2) screw in threaded bar, drop on collar , washer and nut..



Step 3) wind out valve guide..



as easy as:



I had a box of bits arrive..



62 € so far.... with the valve guides that will bring the bill up to nearly 100€...

Cordialement,

Hello,

Well, the valve guides arrived and so duly fitted..

I apologise for the lack of photos here..but I was trying out my new video glasses.. got carried away.. and had the job nearly done before I thought of photos..

So.. Step 1) clean the valve guide hole in the cylinder head..I use an old machine ream to pick up any swarf from the removal of the old guide..

Step 2) align the valve guides by hand

Step 3) Fit the insert, and a 'wobble' socket, then I use an air chisel to drive the guide in:





The guides then have to be reamed..

Reaming is needed because the guide will have shrunk slightly when it has been driven into the cylinder head..

Here is an adjustable reamer.. you start under size and wind the collars 2 turns max for each pass.. use cutting oil..



Note the grease round the top of the guide.. this is to catch swarf.. BE CAREFUL.. brass finings are VERY SHARP and will pass into your skin
soooo easily....You have been warned..


You will know when you have it right, when the oiled valve just drops in with no resistance..




So much for the new exhaust valves..

The inlets are cleaned up:



and so on to the valve grinding..

Here is the new exhaust valve lapped into its seat:



Use a plug of oiled paper (4x2 style). pushed through the bore to clean before inserting the valve..


Now all the valves are prepared.. I now polish the mating flange in the combustion chamber using a spare cylinder barrel:

Lightly ground in..:


and then last thing for tonight..

Use a peening tool .. like a fat flat punch.. to close any cracks around the spark plug hole..

More soon.. Aircooled fans..

Cordialement..

Your last set of pictures are showing,but non of the ones before them.

Wish I could see the pictures, Normally works ok but not on this thread.

I'm not seeing any of them. Odd that it works for some and not for others. Maybe if I had the Google Chrome browser (instead of Firefox) it might work.

Sounds like an interesting thread, but apart from one posting at the bottom of Page 1, I can't see any of the pictures. Tried it at work, at home, on a Mac, on an ipad.....but no joy. You're doing something wrong somewhere....

It seems that you have to sign in to see the pictures - I can't see them with Opera,Firefox or Chrome. It must be something to do with privacy settings or something like that.

Hello,

Oh dear, what am I doing wrong..

I'm using Google photos..and I'm on Ubuntu with Firefox.

Upload, organise into album, click on to see full size, and then copy image location.

I have been having Internet problems, hopefully fixed.. now 'hard wired' to the livebox

Sample pics:





Can you see these alright..

I'll look in later..

Hi Ho Hi Ho....guess where I'm going...

Cordialement,

I can see those last ones

These are fine.

Tried on a number of PC and a phone and logged in but still cannot see the picture

Ah- I don't think google photos (great as it is though) will give you a correct full URL to the actual photo file on disk. Instead it creates a viewable sort of presentation of it, album style. It's not a photo sharing system as such. It's a huge shame and a lot of people would like it to be.

Let's say it will give a public link to a collection of photos, but that collection may well be one image, and it is not a direct link to the image. (You can kind of tell by the link text it gives out when requested)

Sent from my MotoG3 using Tapatalk

I am still having to use Photobucket

Why oh Why oh Why isn't there a search facility on ones Photoshop "library"