Safari Turbo/Megasquirt Fuel Injection Project

[Clonebug]

Yes,
I think it is too, I'm just a bit too jittery......


Clonebug

[sideshow]

Lets assume the worst, and since there is no oil galley under that side of the case one could use paint to seal it.

[Ol'fogasaurus]

I was on the phone to Art and zoomed in on the area (ctrl and mouse wheel). If you do that and then page around, there are a lot of places like that. Art wire brushed the area while we were on the phone and (I think) came to the conclusion that is was just a "casting thing/craze" and not that big of a problem (the case hadn't been split yet so he could look at the area from the inside).

I am sure it would have scared the puddin' out of me too if I had run onto it cold. Any updates Art?

Lee

[Clonebug]

Hey Lee,

I did disassemble my "H" case engine down to a bare case and I have to say that all in all it seems to be in pretty decent shape.

If not for the crack I am quite sure that it would have kept going for many more miles.

There is a bit of wear on the one connecting rod that i removed. I can see a little copper color to the bearing shell but the crank bearings look almost brand new. In fact they look better than the ones in the "AE" case.
There is absolutely no heat damage or blueing anywhere so it never got too hot that I can tell.
I am going to strip it down to just the mag case and take it in for scrap money.

I have not decided what to do yet as I am still pondering the crank thing.
If I use the crank I have it will be a fairly quick assemble due to not have to do any parts shipping for balance but I am torn between doing it right and doing it quicker and a cheaper price.
I really don't think I need much more power than what I was getting with the turbo therefore I am leaning to just putting it back together with mostly stock parts.
I should have my heads checked although they look pretty decent too.

We will have to see what happens in the next few weeks.

Clonebug

[Coyote]

I am torn between doing it right and doing it quicker and a cheaper price.

Well it's up to you, and this is your wallet, but between "doing it right" and "doing it quicker" I will not hesitate. It's always a "pain in the ass", to reopen an engine !

[Clonebug]

Update,

I tore my "H" case down for recycling and now have it down to a bare case with all the studs removed.

I pulled a rod off the crank to check them for wear and found the center one had some good wear on the bearing. It was showing pretty good copper color on it.



The interesting part was the center main on the case.





Probably one reason I had low oil pressure at hot idle.

The lifters and cam showed some wear. The lifters were flat and the lobes showed a bit of wear.

The crank has a little grooving to it but it's better than I thought it would be.



There is nothing I can use on this engine except the heads and I will probably have them looked at. They will at least need to be cleaned up for cylinder sealing.

I also received my cam back from Delta Cams today. It is beautiful!!!
I didn't want to unwrap it due to keeping it from moisture damage but I got their D 10 grind which gives a little more lift for turbo use.

Clonebug

[Clonebug]

Due to the crappy weather we have been having lately.........oh let's see........13 degrees F with a 30 mph wind blowing out of the Northeast which puts the wind chill down to about -10 degrees.... I have not done much with the engine build.

My brother(bless his heart) has offered to front me the money to do this build the right way and now I have even more decisions to make.

I am torn between using the stock crank and keeping the price down.. or going for a counterweighted crank and and bumping up the displacement a bit to get a little more power.

I was looking at the slip in 88 mm P/L set that all you have to do is machine the heads to get the extra thick barrels to fit.
http://www.thesamba.com/vw/classifieds/ ... ?id=806472

I am thinking I should probably have my heads looked at to see if they need a touch up at least on the sealing area if not a quick valve job and it would be easy enough to do a flycut to the 90.5/92 mm diameter to fit these cylinders.

That would mean I would need to get the rotating mass balanced for the counterweighted crank but that would be a good thing I suppose.
I really don't need to rev the engine above 5500 rpm so it is really a toss up as to if this would be worth the extra cost.
All I do is drive it to work and back in the summer and give a few cars a run through the roundabouts which adds up to about 3500 miles per year.
When I have my wife with me I have to behave and make it seem like a putt putt car....

I am getting ready to work up the guts to order parts so we will see in the next week which way I will go.

Clonebug

[miniman82]

You have stockish heads right? Biggest I'd go with those is 1776, IMO.

[Clonebug]

Yep,

Stock heads so the 88 mm barrels would be right around 1700 cc's which should be good enough for me.

That way I can keep working on my blow through carb thing until I win it over....

Getting into a worked up set of heads would put me in way too deep for the cheap thrill that I was looking to start out with.


Clonebug

[turbobaja]

That way I can keep working on my blow through carb thing until I win it over....

Getting into a worked up set of heads would put me in way too deep for the cheap thrill that I was looking to start out with.

IMHO it would be nice to see you continue having fun with at least clost to stock parts and minimal budget. Just to continue showing folks how tough the stock engine is and how much power can be made through the stock carb even . You're biggest advantage is you're vehicle is so light that it makes the power you have seem like half-again as much .

If you step into bigger heads that flow and cost more, you'll be keeping your foot planted until the rpms climb higher and higher. EVERYTHING costs more the higher you want to spin your engine, and weak spots in the build will show up sooner rather than later. Your bro is a generous man, if you play your cards right I bet you'll still be friends after the engine is built and running .

[Clonebug]

Update,

Thanks to Nate at ProVolks for drilling and tapping my case.

We prepped it for full flow and also tapped the rest of the plugs.
I will now give it a good cleaning again. I stopped at Harbor Freight on the way home and picked up a set of cheap tubing brushes and I will get everything spotless for the next stage.
I am just about ready to make the final decision on parts ordering and hope to get one in by the end of the week.

Talked to TimsACVW and will be sending my heads in for a freshening up and possible other unnamed mod....

If everything goes well I might have a new engine to break in within a few weeks.

[Clonebug]

Update,

I have come to a few decisions on the building of my engine.

So far I have this list

AE Case with standard align bore and thrust. (Cleaned, drilled, tapped and Full flowed)
Stock crank polished (.010 under on mains and rods).
Stock cam and lifters reground by Delta cams with their D-10 grind. ( Increased lift from .272 to .299)
Stock 311B rods to be rebuilt.
All Bearings from Aircooled.net
AA 88 mm P/L's (machined heads, slip in case) for added 95 cc's
Stock heads to be machined and rebuilt by TimsVW.
Stock Flywheel
Kennedy Stage I Pressure Plate
CB Performance Super Disc clutch disc.
26 mm Shadeck oil pump with full flow cover.
Stock pushrods
Stock Rockers and shafts.

If I can get 130 hp out of this I will be more than happy.
I plan on limiting rpm to under 5500.
If it goes as well as it was before the case crack I will be thrilled. Since I now have the fuel and a clutch to hold the power it should be a handful.

[Ol'fogasaurus]

It might be a good time to build the under pan body mount tunnel beef up pieces. You’re going to start twisting some stuff now that everything else is going to be more toward the max.

You should also be looking into a cage like we talked about earlier. It is a good place to hang the laundry out to dry after one of those hard commutes to work with the tires and turbo smoking when you get there.

Lee

[Clonebug]

Oh come now Lee......

You don't give me any credit.

My foot has lightened up considerably in the last few months.......

[Ol'fogasaurus]

It's probably true for your wallet too.

I'm waiting... nerviously, for a ride when your done.

Lee