My 69 Westfalia - Oxyboxer engine

[tmatre]

This is my Westfalia camper, imported from California to Norway July 2009

 

[tmatre]

New curtains sewn by me on my wife's sewing machine
Blue and white squares fits nicely to the blue/white door panels and blue seat cover

 

[tmatre]

My home made Continental upper bed.
There are no more than 2-3cm from the bed to the roof, so I selected to use the inflatable camping mattresses in stead of foam

 

[tmatre]

My new engine block:

 

[tmatre]

Water jackets removed with angle grinder

 

[tmatre]

Adapter rings and plugs from Rocky Jennings

 

[tmatre]

AA Performance 92mm thick wall cylinders

 

[tmatre]

Rest of the water jacked milled, head bolt holes plugged, re drilled and tapped with M8 threads.
The block is then glass blasted

 

[dubdubz]

:mrgreen: more more

 

[tmatre]

Test assembly. With 5.5 rods the piston to the cylinder top clearance is 14.2mm included the adapter rings (not fitted on the picture)
I'll will go for 1.2mm piston to top clearance, 55cc chambers = 9.0 in compression

 

[Justin & Muttley]

That looks interesting - what's the thinking behind adapting a water-cooled block?

 

[tmatre]

CB 2280 camshaft and hydraulic lifters (successfully used by some members of the shoptalk forums)
http://www.shoptalkforums.com/viewtopic.php?f=37&t=132973" onclick="window.open(this.href);return false;

CB044 heads

Mexico EFI TB, end castings and generator stand
The TB is a bit to small for the 2021cc engine, but hopefully it will work OK up to 5K RPM
I'm trying to build something that looks stock

 

[tmatre]

That looks interesting - what's the thinking behind adapting a water-cooled block?

Strong alu case.. this is real German stuff.. not bad sand cast
And the 76mm crank with 5 flywheel bolts

 

[Justin & Muttley]

That looks interesting - what's the thinking behind adapting a water-cooled block?

Strong alu case.. this is real German stuff.. not bad sand cast
And the 76mm crank with 5 flywheel bolts

Thanks for the explanation 8)

 

[gninnam]

Very interesting

 

[dubdubz]

That looks interesting - what's the thinking behind adapting a water-cooled block?

It's not an easy engine to build, but gives you better bearing journals [read stronger iirc?], it's a beefier type1...some have issues with the fact the studs have to be moved to match up with T1 heads...there's loads of info on shoptalk forum.
Some argue a alu T1 case and a T1 76mm crank is easier to build, but that's not german parts more likely chinese.

Not sure how the 5bolt flywheel matches to a 1600 gearbox, but I'm sure tmatre will pass on the info

 

[tmatre]

There are some options...
Some use a 200mm T4 flywheel machined for t-1 clutch with pilot bearing
Some uses 210/215mm T4 flywheel with pilot bearing
Some uses 228 flywheel with pilot bearing.
Some change to a T4 gearbox or change the clutch housing / axle to T4 type..

My plan is to use the 228 flywheel with pilot and remove enough material so that the clutch will fit in the clutch housing.
Then I will use a starter from a TDI powered 4 cylinder car, this is a self support type like the Automatic starters, but it is 1.8 kw
Then use a spacer when mounting the starter..
Test fitting is not done yet, waiting for more parts, both new and used.
Will post pictures when ready

 

[sparkywig]

Interesting engine build.

 

[Geeze]

Stock looking 2.2 on EFI is a cool build 8) looking forward to seeing it come together.

What management are you intending to run?

 

[tmatre]

I'm not sure about the management system...
I have used Megasquirt on 3 engines now, and i have another ECU, trigger wheel and what is needed.

Im also thinking about using the EFI system from the WBX engine...

Got a mail from VWParts yesterday.. parts shipped