Club 80-90 Forums

300CE wrote:Nice work

Getting excited Paul?! Can be your belated Christmas present to yourself.

It's going into my Chrismas present to myself

itchyfeet wrote:

300CE wrote:Nice work

Getting excited Paul?! Can be your belated Christmas present to yourself.

It's going into my Chrismas present to myself

Just can't keep a secret can you?

what2do wrote:

itchyfeet wrote:

300CE wrote:Nice work

Getting excited Paul?! Can be your belated Christmas present to yourself.

It's going into my Chrismas present to myself

Just can't keep a secret can you?

What have you bought - gotta tell now?!?!

Every month or so I catch up on This thread and have good read. Interesting stuff :geek:

slowcoach wrote:Every month or so I catch up on This thread and have good read. Interesting stuff :geek:

I'm hoping it will be finished in a month

A great, informative thread

Looking forward to the next instalment.

Heads on tonight

I got some Hymolar AF as suggested by tencentlife

https://club8090.co.uk/forum/viewtopic.p ... 6&start=15" onclick="window.open(this.href);return false;

Had a practice on an old compression ring and a barrel and I found using my finger to smooth it out gave best results

P1060720 by Paul_Barr, on Flickr

next all mating surfaces were cleaned with meths and allowed to dry.

P1060717 by Paul_Barr, on Flickr

green barrel to water jacket seals on

P1060718 by Paul_Barr, on Flickr

Dirko S on the water jacket and the water jacket seal on

P1060721 by Paul_Barr, on Flickr

P1060722 by Paul_Barr, on Flickr

P1060723 by Paul_Barr, on Flickr

Hymolar AF on the head and smoothed it with a small brush, no getting a finger in there, must be a quality brush that does no shed hairs

P1060725 by Paul_Barr, on Flickr

and on the compression rings both sides ( Fire rings as tencentlife calls them)

P1060726 by Paul_Barr, on Flickr

smooth it out

P1060727 by Paul_Barr, on Flickr
place in head

P1060728 by Paul_Barr, on Flickr

coat barrel mating surfaces

P1060730 by Paul_Barr, on Flickr

Dirko S on water jacket seal

Head on

P1060731 by Paul_Barr, on Flickr

Next I added the nuts DRY and torqued to 25Nm, as suggested by Tencentlife this allows the hymolar which is the consistency of treacle to exit from the joint.

P1060734 by Paul_Barr, on Flickr

I left this for 30 minuites then one by one removed the nuts, coated with yellow sealant and torqued back to 25Nm
Once all back at 25Nm I torqued to 40Nm and left for a further 15 minuites before torquing to 50Nm

P1060737 by Paul_Barr, on Flickr

P1060739 by Paul_Barr, on Flickr

Very impressive Itchy...

When are you looking to go all `James May` on us and post the road test.!??

Hoping to put the engine in next weekend
I should have said I'm fitting telescopic push rod tubes otherwise they would have needed to be fitted with heads.

Started fitting tappets today but hit a snag.
As I said if I was fitting standard push rod tubes these would be in when heads go on but with telescopic they are fitted after.


I bought elring seal this time but the ones in the kit were much better than last time.

P1060747 by Paul_Barr, on Flickr

P1060749 by Paul_Barr, on Flickr

I had fitted a few before I noticed this, always pays to inspect new stuff.

P1060751 by Paul_Barr, on Flickr

Fitted water pump new oil cooler and some pipes, all with new stainless nuts and bolts, also fitted a DJ crank pulley, shown here next to a DG you can see the timing mark is further Before Top Dead Centre.

P1060746 by Paul_Barr, on Flickr

P1060757 by Paul_Barr, on Flickr

VW Heratige have promised to send me a new pushrod tube

Needs a new clutch old one is almost to rivets, this Sachs clutch has 2mm to rivets from new, the slots are 0.75mm deep so when you reach the end of the slots you are half way.

P1060759 by Paul_Barr, on Flickr

Clutch alignment tool fitted to keep prressure plate and friction plate together, align them and tighten.

P1060762 by Paul_Barr, on Flickr

P1060763 by Paul_Barr, on Flickr

bolt it up 20Nm and the tool can then be removed

P1060765 by Paul_Barr, on Flickr

torqued the Oil pressure switch I splashed out on a deep 24mm socket, makes it so much easier

P1060767 by Paul_Barr, on Flickr

Oil pressure relief valve in with new crush washer, this is all new one year ago.

P1060768 by Paul_Barr, on Flickr

only way I can find to tighten it is a piece of sheet steel and a spanner, suggestions?

P1060769 by Paul_Barr, on Flickr

Thermostat housing on with all new o rings and new stainless bolts / washers, copper grease also

Stainless exhaust studs in with copper grease also

P1060770 by Paul_Barr, on Flickr

looks great bet you cannot wait to fire it up

scottbott wrote:looks great bet you cannot wait to fire it up

Yes and no, could be great could be a disaster.

Push rod replacement arrived today.

Got it to TDC No 1, rotor arm pointing at notch.

P1060782 by Paul_Barr, on Flickr

some vaseline on the push rod tube seals otherwise they stick and won't hold the seals with the right pressure.

P1060783 by Paul_Barr, on Flickr

quick check the tappets are still solid

P1060784 by Paul_Barr, on Flickr


I don't know where they came from so they go in anywhere, normally I would keep them in the same position. Hole facing up to limit drain down while I adjust them.

P1060785 by Paul_Barr, on Flickr

tubes in

P1060786 by Paul_Barr, on Flickr

pushrods in and use a torch to check they are in place, engine at and angle to keep them there.

P1060788 by Paul_Barr, on Flickr

rocker gear on, I already loosened the lock rings and backed them off two turns to limit pressure on tappets and limit drain down while I adjust

P1060787 by Paul_Barr, on Flickr

back off adjusters for No 1 to touching and two turns to VW spec ( my preference do 1.5 if you like)

I/2 turn clockwise on crank, rotor arm moved a quarter turn clockwise to No 4 ( 1432) then adjust 4, then half turn on crank 3 then 2

P1060792 by Paul_Barr, on Flickr

new gaskets covers on finished

P1060796 by Paul_Barr, on Flickr

all 410 pics here
https://flic.kr/s/aHskY2VufU" onclick="window.open(this.href);return false;

then I noticed mayo engine in the corner
next project
https://club8090.co.uk/forum/viewtopic.php?f=37&t=156893" onclick="window.open(this.href);return false;

P1060799 by Paul_Barr, on Flickr

Bloomin' marvellous job Paul & a fantastic write up - look forward to seeing it in the bus