Oops!!

[benlawlor85]

Thank you so much for this thread. This and the Bentey manual and im hoping to be able to rebuild my CU lump!

[sarran1955]

Hello,

Prepare your comfy seat and popcorn for mid September....

The crankshaft has been to the engineers for consultation..

We are of the same opinion..

The crank is 'limit' useable.. one option being just to grind the nose bearing and fit an oversize shell..

With lower oil pressure than I would like...

So we are going for a reconditioned standard size German core crank from the US..

Even with shipping it is better than a Euro model.... and theirs is a cast chinese rebuild..

Its a VW thing...

Cordialement,

[300CE]

Look forward to the update John once you've received the new crank!

[DuaneEddy]

John

All the engines that we used to build we used a product called Plastigauge to determine the clearances

Saying that - the crank just dropped in on a conventional engine and was not as fiddly as splitting the cases again to look at a piece of plasticine

Just a thought

[sarran1955]

Look forward to the update John once you've received the new crank!

Hello,

The US mail comes in great boxes..

The 'goods in' chap at work always comes to me with a big grin..

I've just bought, again from the States..

a pair of 'reverse' pliers..

http://www.expandingpliers.com/" onclick="window.open(this.href);return false;

To do the hefty expanding circlip on the nose of the crank..

20$ plus postage 20$....

No more struggly (?) circlip pliers and shims for me..

Cordialement,

[sarran1955]

Hello,

Welcome to 'Ooops 2.0'....

This nice parcel just received from the states..



Yes.. there was entry into Europe tax of 72€ on....

The 'Yank crank'...



I hope you can see the difference.......

Briefly, when I tested the motor with the original crank, I was not getting enough oil pressure..

Bearing in mind the history of the crankcase..

I want to keep all dimensions standard...

So an 'in depth' hunt ensued for a remetalled and reground, German origin, machined to standard size crank at the best price..

For the 2 litre engine. all the bits are available in the states at reasonable prices when you include shipping and tax..

The best European offer was from Denmark at 699€, but only available with counter balances (for higher RPM)..

From the States.. standard size crank 199$ + 84$ postage + 72€ tax ... comes out at about 300€ all in....

So here we go again....

This is about as 'spread out' as you can get an Aircooled engine...



I will 'Youtube' video this to show an Aircooled 'crank up' rebuild...

Cordialement,

[horizontal kipper]

What company did you buy from in the states?

[sarran1955]

Hello,

A peaceful Sunday morning got us to here:



Hopefully this will be the last time we see the case open for a while..

Spot of lunch, and then a bit more..



I'm not going into the details again.. but I am doing this rebuild on video..

Monday..

Bit more this evening..

Setting the crank end float...



and the 'show how' on video of the method..



That's it for this evening....

(HK.. what bits are you looking for. .I have several contacts )

Cordialement,

[T25Convert]

Good to see it back together again!

Interested to see your home made looking end float tool - presume that you use a feeler gauge between bolt and what appears to be an angle grinder disc changer?!

I'll watch the video when its ready, seems cheaper than a dial gauge!

Cheers,

Alex

[sarran1955]

Hello..

Good to see it back together again!

Interested to see your home made looking end float tool - presume that you use a feeler gauge between bolt and what appears to be an angle grinder disc changer?!

I'll watch the video when its ready, seems cheaper than a dial gauge!

Cheers,

Alex

10 /10 for observation....

Cordialement...

[sarran1955]

Hello,

I hope you are all still out there.......


The shiny new pushrod tubes arrived..

Sunday engine build..

Aircooled bliss..

Cordialement,

[300CE]

Yep, still here John and enjoying the thread! Look forward to the next update with your new shiny shiny ancillaries

[Ralf85]

Stop talking dirty John!

[Robsey]

I have been subscribed to this thread for weeks so that I don't miss a thing.
I'm also using this thread to learn useful tips before I strip and rebuild my blown DF.

Looking good so far.

[harvey]

Just came across this excellent tutorial... makes me want to have an air-cooled again.

Incredible work, John. Looking forward to the rest of the journey.