Oops!!

[sarran1955]

Hello,

Sorry no Royal bulletin to post.......

35 Celcius at work....

I had a big turbine to weld...

Taking over the started job from the bloke who is now on holiday...

4 1/2 hrs solid welding....

3 litres of iced water.. 2 magnesium/salt tabs....

If I sweat that much... how come I have 8 kilos to lose..

Home.. cold beer.. aircon.. bliss..

Too hot to go out on the terrace.....

Peak of 38 at Lyon and all of South East France on 'Alerte canicule' (heat wave).. so speed limits reduced,,

and extra surveillance of the elderly...

Enjoy your hols in France... drink plenty of Roxanne or St Yorre mineral water.

Supper . shower, bed..

Cordialement,

[AdrianC]

If I sweat that much... how come I have 8 kilos to lose..

Home.. cold beer..

Aye, that'll be it.

[paulandchez]

Sarran.....what a great post!!

I am currently doing the same as you on my engine so this has been invaluable! The Bently is great but your pics tell much more.
Quick question for you....you're using exhaust paste on the exhaust gaskets which I will be doing myself, but for the other gaskets, for example the rings between the cylinders and heads etc....would you use any gasket sealer as well? When I took mine apart, almost every gasket had a bluey rubbery sealer on it which I've since cleaned off. If you have, is there a preferred product, or any to avoid?

Thanks again, and keep posting!!

Paul

[sarran1955]

Hello,

Well this has been a bit of an eventful week...

Lots of thunder storms and power outs... so no internet..

Anyway.. back to the engine build..

This is where we had got to..



the next thing is to check the oil pressure...



Not a happy bunny... oil pressure far too low..

When this happens, you must stop and go back until you find the problem and fix it...

If you go on.. you will drop a bearing and that will be the motor ruined..

So now I take the motor down...

It is much quicker after a rebuild..

2 1/2 hours to get back to the crank..



Pull the pistons with the cylinders... saves using the ring compressor next time..



the exhaust and tinware come off in big chunks..



Right.. so inadequate oil pressure... so lack of flow or lack of pressure...

Pump seems fine.. remember this engine ran OK before the case broke..

Next stop... reconfirm the crank big end journal dimensions..

The original bearings were all standard with very little wear.. so I check the dimensions of the replacement bearings..



Just to be sure..

I take a set of old shells.. and compare with the new..



OK .. recheck with the verniers... everything is well within spec. No reason for loss of pressure here...

Tomorrow I will look at the oil pump.. but it looks pretty inevitable that I will have to re-split the crankcase...

I must confess to being a bit mystified at this point..

There are thunderstorms predicted for tomorrow, so it may be a bit late before I can post again..

Cordialement,

[300CE]

How frustrating John - fingers crossed you find the source of the problem without having to split the crankcase mate

[pionte]

I hate that feeling... the realisation that all your work has to be undone. But that is what separates you from the bodgers

Good luck sorting it out, You will im sure, you wouldnt have come this far if you where the sort of person that gives up !.

[Plasticman]

indeed, so much easier also to fix it and not post this up ,butttt i find it help others when doing a job to show a problem and then the process of finding and then fixing, same with bodies and the like,
good work ,shall be watching as usual
mm

[sarran1955]

Hello,

Thanks for the kind postings..

It would have been nice to have been tunung the engine this weekend..

But it doesn't always happen that way...

So, oil pump off..



I loosen the two case nuts above and below then 2 x 13 mm spanners as levers to start it out ..

then 2 x 27mm to finish pulling it out.. make sure it falls on something soft..



I'll look up a new one I think.. as we are going in again..

Then I wanted to rebuild the big ends....



and broke my thin wall 14 mm socket...

Methinks its time to stop and mow some meadow before the thunder starts..

Cordialement,

[AdrianC]

Methinks its time to stop and mow some meadow before the thunder starts..

What you cutting the grass with? Nail scissors?

Your audience eagerly awaits the next instalment!

[sarran1955]

Hello,

What you cutting the grass with? Nail scissors?

OK, so I will be doing some 'Ooops' stuff this long weekend...

We are still at 43.75 hours/week at work....(Poland wants new stuff NOW)

and I do have at least 1 moped to get ready......

or 2 or 3...

At least I've got the Aircooled Jean Todt red motorhome with Ferrari in the front screen..

for this..




My machinist comes back from holiday soon.. France work closes in August..(lucky them ).... appointment made..

So I will fit the new oil pump.. see if that does the trick..

Do a bit of a video.. then split the crankcase.. and decide whether to re machine .....

or get a new spec rebuilt crank from the States..

like this:

http://vwparts.Aircooled.net/Type-4-Cra ... kshaft.htm" onclick="window.open(this.href);return false;

Unless anyone knows of a NEW Type 4 Crankshaft, 71mm Stroke, 2.0L Journal for sale in Europe..

Cordialement,

[horizontal kipper]

This place is very good for VW type IV Porsche 914 motor stuff http://www.ahnendorp.com/VW-270/VW-Typ- ... ausch.html" onclick="window.open(this.href);return false;

[sarran1955]

Hello,

Well despite changing the pump.. there was no increase in oil pressure...0.8 bar..

So I split the crankcase..

As I wanted to recover the oil seals.. instead of using my case splitter..



I did the job like this..

Using 2 old big end shells and an expander bolt in the oil pump housing..



and a Renault clio jack on the other...



The case comes apart nicely...



and then lifts off...



I have now stripped the crank..its now in a box with all the relevant bits awaiting the machinist's advice this week..


Oh.. by the way, as of Wednesday 14 Aug I am now a grandfather...James Thomas 3.5 kg..


Cordialement,

[81AirCooled]

Congratulations on the grandchild John. My 5 year old's middle name is James, a fine name

[300CE]

Congrats on becoming a grandfather John & I also agree that James is a great name - it's the name of my little un'!

[boardmonkey]

Oh.. by the way, as of Wednesday 14 Aug I am now a grandfather...James Thomas 3.5 kg..

Congratulations !

Such a well written post, bloody brilliant