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  30 year old engine - built and rebuilt by Vallero's VW Werks

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dsimas

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Posts : 788
Join date : 2011-06-02
Age : 55
Location : Auburn

PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks   Fri Feb 14, 2014 3:10 pm

Ray gave all the tins to my husband Tom for him to seal all unnecessary holes and then to paint them.  There are a LOT of pieces!











Welded.





He painted them a hammertone color that matches the Silver Platinum of the bus interior.  Way to go Tommy!



Here is the painted tin going on.  Ray will seal the gaps with silicone sealer.



Assembled, with the deep sump back on.



A new alternator stand.  This motor had a generator previously.



Zero end play on this new alternator -- unheard of lately!



It's a beautiful thing!





Put the pulley on to check the deck height.



The deck is .208 now.  Before cutting the cylinder, he has to finish the heads and cc them so he knows how much deck to have.





Beginning of the 94 boring.  As you can see, he has a ways to go.  Smile

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dsimas

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Age : 55
Location : Auburn

PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks   Mon Feb 24, 2014 9:36 pm

Now it's time to do the heads!

This is a universal fixture that Ray has in the shop that he has adapted for VW heads.



Ray has drilled the heads for more air flow. This was discussed earlier in this thread. There are now 24 holes in each head. This picture is around the exhaust port.



This is what is left of the original valve seat. He must cut it out. The old exhaust seat is still in place.



My new intake seat, before being installed into the head.



Valve seats installed.



These are tools for cutting seats and throating seats after installed.

From left: 1) For cutting the seat pocket for a new valve seat. 2) A curved cutter installed for shaping around the seat pocket in the combustion chamber. 3) For topping the seat after installed. 4) A 75 degree throating tool.



We will now be removing the production valve guide that comes in the AutoLinea head and then putting Ray's own valve guide in.



Machining a flat spot down in the port for the new valve guide. This way it will not be pushed off center as it comes into the port.



There is an unmodified stock valve guide sitting next to the four intakes that Ray has modified. Putting this taper on them makes them flow better.





Note how we can actually see where the intake bolts on from this side of the cylinder head.



He is now boring out the inside of the intake seat area



This shows the flat spot and the beginning of unshrouding the valve pocket.



Unshrouding is very visible here. By leaving the flat areas on purpose, it results in an active combustion chamber charge.



Begining of the blending the port.



Here is a stock one.



The combustion chamber is almost complete.



Ray is making sure that the valve height is the same on all holes, so that we have equal breathing in each cylinder.



94 x 74, 54 cc's, 8.64 compression ratio, the deck yield should be .075. We started with .208 deck height, so we need to cut the cylinders .148. Then we will end up with .12 deck height, plus the .060 head gaskets.

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Bugman66

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Age : 74
Location : Auburn

PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks   Sat Mar 01, 2014 2:15 pm

Dawn: Great series of photos and comments. We are fortunate to have Ray in Auburn. He is the best.
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dsimas

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PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks   Mon Mar 03, 2014 4:15 pm

Here is a cylinder on the mandrel.  The barrel is going to be shortened by .208. Removing the fin on the bottom makes room for the case nuts or any other small obstacles on the case.



He has two cylinders cut now.  This picture shows the .060 head gasket in place and it *just* slips into the hole with zero clearance.  He can now establish the pushrod length.



They are 10.975" long after measuring everything.  In this picture, the old pushrod is below, the new one is above it.  It is now 7/16 on one end, with a straight taper to 3/8 on the small end because of clearance needed at the rocker arm end.  Large dimensions like this make an extremely stable valve train.  Aluminum is quieter because it dampens shock.  This also makes it easier on the valve train and the cam shaft.



Ray is measuring the cylinders here, checking that they are all exactly the same way after cutting. He had to do a little touch up on a couple of them.  Now he will hone them.  Within .0001 (average human hair is .0004).



Doing some fitting, it's a bit narrower so he will shorten these studs. After that he will do a valve job on the cylinder heads and start the assembly.



All 16 head studs have been shortened to accommodate the narrower combination.



We are going to have to bead blast the manifolds because these fuel stains will not come off. The clean spot is from modifying the manifold for clearance of the tin, something he always wanted to do but he's never had them off.



After:



These needs some love.  Dual 40 Webers, once dialed in decades ago, we never had to touch them.  Smile

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MichaelKersten



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Join date : 2011-11-11

PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks   Fri Apr 04, 2014 1:01 pm

Awesome. thanks for these pics and
comments.
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