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Frustratingly, the oil piston puller (Part no AC000117) doesn't fit my pistons! But as if by magic I found my Grandad's old tap set and managed to extract them with the 1/2" tap: https://photos.app.goo.gl/81geGNdhuK4pfQJw5 The pistons measure 16mm outer diameter, and 12mm inner diameter, and...

Back again! I'm in a much better place now, both mentally and physically (moved in with my fiancee, all grown up) and have finally had the bus moved to my new house so I can get back to work on it. I have prepped everything for the first run of the engine, and it's turning over nicely on the...

OK I've had a couple of days on the bus, cut off the remaining bolts and replaced them will CSP sump studs, however, one of them is already a stepped stud, and another is really loose so it needs a thread insert. I need to get this bus started, so I decided to go ahead and bolt the sump plate...

Thanks George—I've updated with links to my photos in google for now :)

Now the bolt is removed, here is a blurry photo showing the insert—it looks like all the bolts have these: Photo link

Managed to cut the bolt off! I'll need to do an engine oil flush to get any contaminants out before I start it so I think I'll cut the other bolts off (apart from the one that holds down the oil shield), in the same way, to avoid having to do it in the future. This should also solve my next...

There are already some form of thread inserts in there—I'm not sure what kind they are or what size, I'll get some closer photos when I manage to get the bolt(s) out. I don't know much about thread inserts, a couple of these are slightly wonky but hopefully, they will hold oil with the proper...

For those interested, I have some rotary cutting discs arriving tomorrow so I can try cutting the head of the bolt off. Here is a photo I took today after winding the stripped bolt up as far as possible until it hits the oil shield thingy: Photo link I considered cutting the thread off outside...

Thanks Mike, I don't really want to swap the case, I just want peace of mind. The bolts—though they are the correct M6 diameter—look as though they are inside case inserts of some sort so I'm not sure I can remove these and re-tap for the over-side studs... If they were all square I would just...

My current 1600cc twinport engine case has bolts instead of studs to secure the oil sump plate—obviously, one has stripped and the engine is leaking oil, so it requires the engine removing and the case splitting to extract it and replace with the correct specification sump studs. This engine...

Thanks fellas, it just wasn't screwed in properly, lord knows why I missed one. This engine build has been interrupted too many times!

It hasn't moved during head torquing, it was already longer than the others. Trouble is I put the (brand new) studs in quite a while ago so can't remember the reason behind it. Is it safe to remove a single stud and re-insert it, or would I have to remove the head, associated barrel and piston?

...I noticed I hadn't screwed the pedestal studs in all the way which was stopping the rocker arm from seating properly...ahem... anyway another issue, one of my head studs is longer than the other and is preventing the left-hand rocker shaft from sitting flush...

My rebuild thread might be of interest, I replace the entire roof panel and did numerous repairs to the gutter, there are some interesting photos and videos on here: http://forum.earlybay.com/viewtopic.php?f=2&t=62017

I have built up my standard 1600cc engine using the 043101355CK heads...

You sir are an absolute saint! Jonathan McMillan at AA has confirmed that the photo is indeed wrong, I will be placing an order with them shortly. No mention of the 15% discount, I will ask them again about that. Thanks for all your help!

So let me get this right: 043 are the genuine brazilian VW heads ( 30 x 33 ) and are the money no object first choice 040 are the AA heads ( 35.5 x 32 ) and are a highly recommended aftermarket head Or, does the "040" or "043" just refer to the mould, with several different companies able to...

Thanks for all the advice guys, could you please explain to me a little more about the "AA 043" casting? Who makes these heads and where can I source them new?

Thanks vinvan, I have messaged him directly so hopefully he will be able to shed some light on the matter in this thread.

I'm about to purchase a set of dual port cylinder heads for my stock 1600cc motor, but I don't know which to go for. There seem to be 2 common types, Auto Linea ones and EMPI ones. At Machine7, the Auto Linea ones have been recommended and are slightly more costly, but at most other outlets...