1970 Westy Pop Top

[Cali_bay]

Started on my latest project a few weeks back. Thought I'd give an engine build a go. Had to urge for a bit more performance and after reading an artcle on a reliable 'Tractor Engine' for a bus in Hot VW's magazine a mate brought back from the US the seed was planted.

So here goes.

Used slide hammer to remove case plugs to clean the galleries. The drilled and tapped to fit plugs.

Clearanced case for new crankshaft. Took about an hour a side with a Dremel, my new favourite tool . I went steady and kept checking the crank clearance as I went on.

Had to take some of the camshaft bearing pillar.

Next got the case step bored and decked for 90.5's, a collegue at work did a great job on this.

Next tapped out the feed hole from the oil pump ready for full flow. I also plugged the pump as well.

Longer fixings for deep sump. I went for a CB slimline one for ground clearance.

Now on to cleaning measuring and checking all the parts. Learning as I go.

 

[Cali_bay]

Picked up my engine parts from the Basset Down Balancing.

All looks good, balanced the pistons, rod and crank assembly (flywheel, front pulley and clutch plate). Also they dowelled the clutch plate to the flywheel to ensure correct alignment. The parts can be replaced individually if required in the future as well.

The next job on the list is a dry assembly of the bottom end and fit the barrels and pistons to measure the deck height. I also have to cc my heads to calculate the correct compression ratio. This build is going to be set at around 8 : 1 as it’s reliable torque I’m looking for not overall power.

 

[creationblue]

Nice work Si 8)

 

[K@rlos]

What cc is this motor gonna be? 90.5's a stroker crank sound juicy 1955? 2007? 2110? :msn4:

 

[Cali_bay]

What cc is this motor gonna be? 90.5's a stroker crank sound juicy 1955? 2007? 2110? :msn4:

Hi K@rlos,

It's going to be a 2027cc. Not going for Ball's out performance, just realiable torque, hopefully.

Cheers,

Si

 

[Cali_bay]

Nice work Si 8)

Thanks Just.

Just trying to take my time with it, hopefully do it right. :?

 

[Cali_bay]

A bit more progress today. Carried out a dry build ready to measure deck height and to find out what spacers are required. Also ready to calculate the CR (aiming for circa 8:1)

First off fitted rod shells and then rods to the crank shaft.

Next fitted to cylinder studs

Placed the crank into the case. I have not fitted the gears yet as I will be stripping it down again after doing the deck height and cleaning all the parts again.

Then the camshaft, the case was fitted with a thrust bearing in both case halves. One needed to have the tang filed off to allow it to fit in.

Fitted the two halves together and torqued up the nuts in stages checking the crank and camshaft rotate each time.

Finally fitted one piston, before I ran out of time.

Next jobs to do are fit the barrel 1 and then repeat for the rest of the cylinders.

 

[cotswoldiver]

Aren't you having fun .... 8)
Good to see Simon

 

[Cali_bay]

Aren't you having fun .... 8)
Good to see Simon

Hi David,

Yes it's good to have something to be getting on with. I've had to go back a number of steps (well strip it back down again) as I needed to do a bit more clearancing, which I only found out after torquing it all up and rotating the crank with the piston in place. Doh!

This now means I have to give everything a good clean and wash again before I can build it up again and do the deck height and CR measurements.

How are you and how’s you bus?

Si

 

[sparkywig]

8)

I may be giving you a call at some point.

 

[Cali_bay]

8)

I may be giving you a call at some point.

No worries, I give you a list of what not to do...... :lol:

 

[sparkywig]

What are you doing for heads, cam and carbs?

 

[Cali_bay]

What are you doing for heads, cam and carbs?

I am going for a c35 cam again recommended for torque and CB 044 heads, I still need to decide on carbs, but i was thinking Dell40's. From what I have read and advice I have been given this seems like a good combo.

 

[sparkywig]

I've got stock heads with 35.5mm inlet and 32mm exhaust.
Been advised by Laurie Pettit that these stock rockers, a C35 cam and twin 40's will be OK for my 2056 up to 5500rpm.

 

[Cali_bay]

I've got stock heads with 35.5mm inlet and 32mm exhaust.
Been advised by Laurie Pettit that these stock rockers, a C35 cam and twin 40's will be OK for my 2056 up to 5500rpm.

LP certainly knows his stuff so I would not argue with that.
The 1600 heads I had were Mexican VW ones and I was advised by a number of people that these would not breathe enough for the engine as they have small valves (apparently OK for a turbo engine though :shock: ). I am also following a build from Hot VW magazine which uses a similar valve sized head.


Build Update

I have now managed to carry out the necessary extra clearancing and I now have started building it up again. :roll:

A quick check on deck height (I have not done it correctly yet i.e. checked the head cc and the TDC with a DTI), but I get approx. 1.88mm from piston crown to the top of the cylinder. This would give a CR of 8.55 : 1 which may be a little on the high side as I was looking at 8 : 1 or lower.
The 8.55 : 1 would give more power, but also create more heat. So my options are cylinder spacers or a copper gasket or a combination of the two. I will get some more pictures up or the deck measurement and cc’ing of the heads.

 

[Cali_bay]

Carried on the dry build and now have the engine upto a short block + Barrels and pistons

This plate is to be torqued up to allow the measurement to be taken from the cylinder top to piston crown at top dead centre (TDC). This gives the measurement required to calculate an accurate CR. This will be carried out on all cylinder to check that they are all equal.

I've also started on the heads. I have begun cleaning up the chambers and then I will cc them to get them all equal.

Perspex disc and syringe for measuring the chamber cc

 

[sparkywig]

 

[68_early_bay]

Cool work 8)

 

[Myvanway]

Awesome work. 8)

 

[leon]

Looks good 8) understanding wife too...........engine on beige carpet :shock: