DJ2.1 Rebuild

[maxstu]

brilliant work mate, been following this from the get-go. I've refreshed a load of IDI diesels but this is why I always ran away at splitting a flat four case.

I will be honest, it is the accurate measuring of crank journals, pistons and cylinders etc, giving me grief. Even with an expensive micrometer (which l do not own). There is a knack to measuring correctly. Fortunately, l have a good pal called Jon. He's an old school pattern maker. So use to measuring to 0.000 mm.

Then making sure everything is absolutely squeaky clean in a grubby workshop more suited to gardening/DIY hard landscaping and decorating equipment.

[tobydog]

ideal tool; a heavy and a strong platform to hit with a club hammer.

Set the crank upright on a solid surface. Or fit a flywheel. Align the gear to fit over the key and start whacking with (ln my case) axle stand shaft until cam gear is against the shoulder on the crankshaft.

Blimey, tractor repair in the field, shed, barn, ditch.....

Keep whacking!

[Cecil]

The hammer and pipe is fine but whatever you do get any kitchen equipment cleaned up and back in the kitchen before the lady of the house notices.

[maxstu]

The hammer and pipe is fine but whatever you do get any kitchen equipment cleaned up and back in the kitchen before the lady of the house notices.

Saucepan and lid out of camper. And that's MY domain...so Maxine tell's me!

[Stesaw]

Whatever works Stu . Good to see you progressing. The whole thing about drilling the oil holes in bushes made me think, Oh "pooh" did mine need doing and just assumed and I didnt check? But I'm 90% sure the Heritage set were all done and just needed to be fitted.

[maxstu]

An update on this rebuild.

I gave the rods to Jeff at the beginning of the month. I rode up on my workhorse Honda Biffer 1000 motorcycle in torrential rain and met my Dad (The GOAT), who lives nearby, at Jeff's place.

The old GOAT, at 91, still drinks and eats like a horse, and reluctantly gave up motorcycling/sailing only last year!

The GOAT.



A proper man cave.



Jeff at work.



The same day l rode the 70 miles back home to Margate. And again in horrible rainy conditions. The next day l get a call from Jeff's wife. He has been taken ill and she has sent for an ambulance. Later we hear nothing fatal has befallen old Jeff. Just a continuing complication.

On Jeff's wife's suggestion, l collected the unfinished conrods, as she is not certain when he will be ready to continue working again.

So three days' later l rode (yet again in foul wet weather) the 140 miles return journey on my trusty Honda. Got home wet through and spend the next five days' with a horrid cold.

So, back to the engine....

Gave the conrods to Thanet Engine Centre to ream and hone the small end bushes. £80.00.
A week later they are ready to collect. That all done, l gave the rods a thorough clean, added cleaned bearing shells and started weighing up to the find best match for piston/pin/rod combination. Came up with this. Not bad at all....

Adding conrod/crank shells.



Weighing everything twice.



Within 2gms. That will do me. Note new gudgeon pins. New circlips will be used, too.



Crank cleaned and ready to receive rods.



More of that tomorrow or Friday. Put to bed for now. Night, night!

[Stesaw]

Good stuff stu nice to see it's coming along. That some fancy old school mancave stuff going on there. If I recall I put my heavier rods nearest the flywheel so 1 and 3, all my pistons weighed the same so was lucky in that respect.

[maxstu]

Hello Steve, how's the house move coming along?

I did move thing around to get ultimate balance. And this is the best l could come up with...

With one combo piston/rod/pin weighing 1307 grams, two others' at 1306, and last combo weighing 1305, respectively 4, 1, 2 & 3, and using three original pistons, and one gratefully supplied by Andrew at Campershack, l'm obligated to keep three pistons in their original barrels.

More minor issues looming...

The new camshaft bearings are not correct. The largest bearing (out of three), one with a collar, are manufactured with retaining tangs. Whereas the original VW bearings do not. See photo.

Original camshaft bearings against new ones. No tang, you!



Speaking with Simon at B/W (a regular visitor to Margate. Top fella!) it turns out JP, for Mahle, have been incorrectly making cam bearings for the late DJ2.1 camshaft.

All sorted in typical Brickwerks, no drama and customer satisfaction is paramount, style. Refunded without question.
Cheers Simon.

Apparently, l can still use these bearings by simply grinding off the tangs. If anyone know otherwise, then please speak up. Dremel coming out tomorrow.

Stay tuned ......

[Jilldub]

Nice one Stu.
Great to see old school engineer at work and a photo of your dad.
They don’t make them like that anymore!

[maxstu]

Nice one Stu.
Great to see old school engineer at work and a photo of your dad.
They don’t make them like that anymore!

Hi mate! Hope you are well? Yep, neither machines or men.

It will be a truly sad day when he rings the bell at the pearly gates. The last in our family of the older generation.. He got a good few years' ahead of him, though.

Just this September he was at Brandshatch driving supercars. Managed a very presentable score too from the instructors.



This coming weekend in a Spitfire simulator at Manston. Then the real deal over Beachy Head in the spring 2023.

[maxstu]

Not much happened with the engine today. Got caught up helping an elderly neighbour after her newly acquired rescue cat wrecked the curtains in her lounge.

In the afternoon, l washed out the pushrod tubes. Gave them a proper clean inside and out. Then extended each one to minimim size of 194mm. This measurement is NOT end to end. It's corrugated body only.





Genuine VW pushrod tubes. Shiny, shiny!



More proper stuff tomorrow.

[Stesaw]

Hello Steve, how's the house move coming along?

Apparently, l can still use these bearings by simply grinding off the tangs. If anyone know otherwise, then please speak up. Dremel coming out tomorrow.

Stay tuned ......

Slow Stu, got this LT to sort before and get my stuff up north, mrs is already up there.

Yeah now you mentioned it I just ground the tangs off the ones I had, being careful to make sure I only remove the tang material and not going into the wall of the bearing.
 

[Jilldub]

Nice one Stu.
Great to see old school engineer at work and a photo of your dad.
They don’t make them like that anymore!

Hi mate! Hope you are well? Yep, neither machines or men.

It will be a truly sad day when he rings the bell at the pearly gates. The last in our family of the older generation.. He got a good few years' ahead of him, though.

Just this September he was at Brandshatch driving supercars. Managed a very presentable score too from the instructors.



This coming weekend in a Spitfire simulator at Manston. Then the real deal over Beachy Head in the spring 2023.

Stu. I don’t even know the bloke but where I live he’s known as a Legend! Enjoy your times together.
 

[maxstu]

Cheers, matey.

Oh yes! He is such a fun character to be with. Always joking and laughing. And still as sharp as a knife and as bright as a button.
He takes some beating for sure.

Thanks again.
Stuart

[tobydog]

That some fancy old school mancave stuff going on there.

Colchester Triumph 2000, takes me back to 1976.

More like a museum

I wonder how many `engineers` would have a clue what to do with it...

Some of my mates:

https://www.fanuc.eu/uk/en/robots/robot ... ate-200-id

You do not even have a clue