Cali conversion in split bus using CSP parts

[mark-s]

Some pics of my ongoing project. The engine spec is basically stock 2L:

• CU code case
  Reconditioned AMC heads
  Stock 71mm crank which just needed a polish
  Stock rods
  new 94mm Mahle barrels and pistons
  Web 86 camshaft
  Scat lube-a-lobe lifters

The CU case has an enclosed breather tower so it has to be machined down.


Case has been align bored .25 by Stateside Tuning here in the UK. The only bearings they could supply were for thrust cut cases, so the #1 bearing had to machined to fit my std thrust case.


Apart from the align bore and head reconditioning, all the other engine work and assembly was done by Paul Weeding at LVH Engines. This pic shows the CSP head shrouds, alt stand and pulley wheel.

[mark-s]

I have Joe's manual, so I did the cooling modifications:

[NextGen]

Nice Job, when guys show me their Cali Conversion it reinforces what I have been saying for years, each one is unique. Stock tin cylinder covers or fiberglass CSP. Simple oil cooler support bracket. Custom by owner.

If you did not see this video, up the volume and enjoy!!
https://www.youtube.com/watch?v=deD2JxpUA48

[mark-s]

The top of the cooler is held in place by a modified original type 4 bracket, and a rivnut in the back of the shroud.

[mark-s]

The fanshroud modifications complete, I just need to make a piece to fill the void next to the base of the cooler.

[NextGen]

Wow, nice work on the oil cooler!

[mark-s]

Thanks for the kind words Joe!

I read elsewhere on this forum that the 1/4" fittings were a tad narrow and that 3/8" was a better option, so I bought some 3/8 fittings, redrilled and tapped the adaptor to suit.

[wreck]

I like the use of the drill press to start the threads square , a mate showed me that a few years ago and I thought at the time , now why didn't I think of that .
I'm in the process of fabricating a "Cali" style for a 2.6 to go in a Ghia , slightly different though , I want the Fan centred and also will have it blowing down the centre of the pair of barrels .
http://www.shoptalkforums.com/download/ ... w&id=18088

[Piledriver]

Take a look at FJCampers insert thread (in testing mode now)'

Provides uniform airflow side to side.
Its made for the CB centermount shroud, which doesn't.

I may go there too as it makes the packaging so much easier for the carbs or TB setup..

[wreck]

http://www.shoptalkforums.com/download/ ... w&id=18203
http://www.shoptalkforums.com/download/ ... w&id=18204

Starting work on the shroud, making a timber plug , then I'll make a rough fibre glass shroud and start testing air flow . Once I get that far I'll start a thread on it , slow process at the moment as working a real job 6/7 days a week at the moment

[mark-s]

After a trial fitment of the distributor, it was obvious that connecting a hose to the LH oil cooler port using a straight connector would mean the distributor wouldn't fit, as the hose would be directly inline with the cap. I added a 90 degree adaptor.



I'm not 100% happy with this setup for a couple of reasons:

• It adds an extra joint which could potentially leak
• The 90 degree bend will affect oil flow
• The RH port will work ok a straight connector, but means the oil hoses pass either side of the distributor which seems like a clumsy solution

I will keep this setup until the engine is run in on a test stand, then I'll have another think about it.

[mark-s]

Started work on the heat exchangers. I only want the headers so it meant removing the casings and then cutting the cast aluminium fins off using a combination of reciprocating saw (sawzall), hacksaw, hammer & chisel. Quite hard work.

[NextGen]

Hard work but nice end product. They are not exaclty performance headers but they have a factory fit and will last forever. O and saved you big bucks.

Nice

[mark-s]

Fast-forward a bit. I spent a lot of time working on the tinware, using a mixture of fabricated parts and modified stock parts. I was obessive about sealing any gaps and have used U-channel rubber seal and neoprene strips to help.

Click on the pics for full-size images.

Got cooling & oil all connected, fired up on a stand to break the cam in.


test fit in van in preparation for tinware fabrication


Fitting the flaps to the shroud. The themostat isn't connected (yet), I just have the flaps in the open position to help direct the air.


More tinware fettling:





Vintage Speed headers and exhaust.


These were spendy, but the alternative was to spend days - if not weeks - modifying stock parts to fit. I just don't have that kind of spare time so I just bit the bullet. They are nice parts though, well made and they fit first time.

[NextGen]

As for the expensive exhaust, not really!!!

I have my stainless steel exhaust on my bug for 20 years. Before that I must have went through countless systems.

Yes we bit the bullet but it will be worth it. Just don't back up into anything.