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

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dsimas

dsimas

Posts : 788
Join date : 2011-06-02
Age : 56
Location : Auburn

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Empty
PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks    30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 EmptyFri 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!

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Tins

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20130929_123846

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20130929_122905

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Pbucket

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 IMG_0909

Welded.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 332bdf40-5933-488f-a3e3-191293a95e4a

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 IMG_7838

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 IMG_0976

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet36

Assembled, with the deep sump back on.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet32

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131203_152224

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131204_091859-1

It's a beautiful thing!

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet31

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet30

Put the pulley on to check the deck height.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet34

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131204_091530

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131204_132504

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131207_092421
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dsimas

dsimas

Posts : 788
Join date : 2011-06-02
Age : 56
Location : Auburn

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Empty
PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks    30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 EmptyMon 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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131104_154910

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131109_090459

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131207_105928

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131207_104803

Valve seats installed.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131207_104453

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet50

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet64

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet52

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131212_155340

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet65

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131213_100904

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet61

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131207_155717

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131208_154029

Begining of the blending the port.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131208_124406

Here is a stock one.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet62

The combustion chamber is almost complete.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131208_134906

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131208_153452

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131208_142040
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Bugman66

Bugman66

Posts : 52
Join date : 2012-03-18
Age : 75
Location : Auburn

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Empty
PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks    30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 EmptySat 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

dsimas

Posts : 788
Join date : 2011-06-02
Age : 56
Location : Auburn

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Empty
PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks    30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 EmptyMon 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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131210_092043

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131209_154242

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet55

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).

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131210_101821

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131210_100837

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131211_084329

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.

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131210_130931

After:

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Velvet63

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

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 20131212_103703
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MichaelKersten



Posts : 32
Join date : 2011-11-11

 30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 Empty
PostSubject: Re: 30 year old engine - built and rebuilt by Vallero's VW Werks    30 year old engine - built and rebuilt by Vallero's VW Werks - Page 2 EmptyFri Apr 04, 2014 1:01 pm

Awesome. thanks for these pics and
comments.
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