Oxyboxer build thread

[Steve Arndt]

A lot of people run with an external cooler only and no doghouse cooler. Miniman, and Stripped66 for example.

[fastback]

put an sandwich adapter under the stock oil filter and run to an external cooler.
or put the cooler in the return line from the drysump.

[andy198712]

Is it common to use t1 heads on oxy's then?
I'm new to the oxy game.

If this build is anything like your 1835 build it'll be amazing!

[grelland]

Thanks for your replies, guys.

A plan is forming in my head, but a couple of questions along the way:

1) Is an inline external cooler with no thermostat be a good idea? I am concerned about not reaching optimal oil temp if all the oil is cooled always. (I know Jørn (fastback) propsed that then I am driving too slowly...)

2) Not having mocked up the entire engine incl excaust, will there be space issues by using a sandwich thermostat under the original filter?

Thanks again

[grelland]

Is it common to use t1 heads on oxy's then?
I'm new to the oxy game.

If this build is anything like your 1835 build it'll be amazing!

Thanks for the kind words.

Yes, T1 heads is "common" on oxys. However the stud pattern differs somewhat from wbx, so there is basically three options:
1- Reposition studs in the case
2- Buy un-drilled T1 heads, and machine stud holes in a wbx pattern
3- modify T1 heads to "fit" wbx pattern.

At the moment I am leaning towards no 3, but I will need to get my new heads delivered, so I can have a closer look.

[grelland]

On the note of stud pattern:

I trial mounted the barrels the other day, and with using 8mm studs, this is the clearance with a std wbx pattern:

pinnebolt.jpg

Based on this, I will attempt to slightly enlargen the stud holes in the heads, and see if I can get away with not relocating the studs in the case

[grelland]

I had a short visit in the garage today, and decided to measure the rod bearing clearance, and using platigage, the measurements came out like this:
mm
1 0.08
2 0.05
3 0.08
4 0.10

I see the Haynes manual states 0.02 - 0.15mm so I am well within that, but I have also seen people refer to 0.001 to 0.002", which gives 0.025 to 0.050mm, and then I am outside.

Anyone that would be concerned with these numbers?

[andy198712]

did you fit inserts and then the 8mm studs? also how did you over come the cylinder OD to case ID issue?
quite tempted my self!

[grelland]

For this mock-up I have used the stock studs, but my plan is to use inserts and 8mm studs with M8 threads.

The cylinder OD to case ID issue will be solved by machining down the barrels to the right OD. They are too long as they are, so I will have them machined, but not the "stock" T1 OD, but one that just fits inside the case. I just need to mock up the engine first to measure the deck height in order to determine how much I need to shorten them.

Go ahead, this is fun

[andy198712]

cool stuff!

just need to find a case!

[Stripped66]

I see some people add an adapter and a bracket so that they can use a doghouse cooler. With the planned external cooler and the external oil tank, will need the doghouse cooler, or can I get away with the external one only?

This decision is entirely up to you. I ran Rocky Jennings adapter on my oxyboxer when I was still running the stock-style cooling shroud:
http://images.thesamba.com/vw/gallery/pix/378317.jpg

The stock oil cooler is an excellent design, and Rocky's adapter keeps the oil plumbing short and simple.

Since changing to a 911-style shroud, I've used only an external cooler. I previously used a 96-plate Mesa style cooler, and only recently switched to a smaller Setrab cooler. The construction of the Setrab cooler is superior and more efficient than the Mesa cooler.

[Stripped66]

I had a short visit in the garage today, and decided to measure the rod bearing clearance, and using platigage, the measurements came out like this:
mm
1 0.08
2 0.05
3 0.08
4 0.10

I see the Haynes manual states 0.02 - 0.15mm so I am well within that, but I have also seen people refer to 0.001 to 0.002", which gives 0.025 to 0.050mm, and then I am outside.

Anyone that would be concerned with these numbers?

I would try to borrow a bore micrometer to check your bearing clearances. Set a standard micrometer to the diameter of each journal, zero the bore micrometer to the standard micrometer, then measure the inside diameter of the bearing while torqued within the rod to determine the clearance. I do not trust Plastigage measurements one bit.

[grelland]

I see some people add an adapter and a bracket so that they can use a doghouse cooler. With the planned external cooler and the external oil tank, will need the doghouse cooler, or can I get away with the external one only?

This decision is entirely up to you. I ran Rocky Jennings adapter on my oxyboxer when I was still running the stock-style cooling shroud:
http://images.thesamba.com/vw/gallery/pix/378317.jpg

The stock oil cooler is an excellent design, and Rocky's adapter keeps the oil plumbing short and simple.

Since changing to a 911-style shroud, I've used only an external cooler. I previously used a 96-plate Mesa style cooler, and only recently switched to a smaller Setrab cooler. The construction of the Setrab cooler is superior and more efficient than the Mesa cooler.

I will be using a dry sump, so the oil will come out of the case anyways, so I guess I will end up using an external cooler. Thank you for sharing your experience.

[grelland]

Not much progress here. Work is eating all my garage time...

But I got some goodies in the mail, including a key element for next year's upgrade:

turbo.jpg

During the weekend, I plan on checking the main bearing clearances before I send the crank and flywheel out for balancing.

The heads are due in a couple of weeks also, so then I can finally start some serious work on this engine

[grelland]

While waiting for some parts, I am planning a dry sump tank in the space behind the rear wheel in the Ghia. But does anyone know what sort of oil capacity I will need? I see CB sell tanks which are 12 qts, but is'nt that quite big?

Any inputs?