my new engine build

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my new engine build

Postby caveman » Wed Jan 01, 2014 9:38 am

well looks like ive got to build a new engine for the splitty, as the old one is kippered . im looking at building a 1776 with scat c25 cam and twin kadrons hopefully it will last longer than the last engine 8) I will be receiving help along the way as I am no engine builder so carl has said he will give me advice along the way which will be very apprieciated also my friend ade from cornwall has said he will help as well

ill get some pics up as soon as I have some 8)
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Postby JOE » Wed Jan 01, 2014 12:05 pm

just do not forget the pics matt :D
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Postby muddy » Wed Jan 01, 2014 12:07 pm

No sneaking Xmas trees in the pics :lol:
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Postby JOE » Wed Jan 01, 2014 12:15 pm

:lol: :lol:
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Postby caveman » Thu Jan 02, 2014 6:52 pm

muddy would I do that???

8) 8)


it is rather like a red rag to a bull though lol :wink:
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Postby GBHgpJON » Thu Jan 02, 2014 7:32 pm

caveman wrote:
it is rather like a red rag to a bull though lol :wink:


Its times like this I'm glad I'm a moderator............... :twisted:
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Postby caveman » Fri Jan 03, 2014 5:19 pm

Not everywhere ya not!! 😝
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Re: my new engine build

Postby caveman » Sat Feb 22, 2014 7:10 pm

i have got started!!

the crank and case were sent off to stateside vw for the case to be alignbored and tapped for full flow. the crank was exchanged for a genuine vw crank that had been reconditioned and cleaned he supplied the correct bearings for the build.

Image

here is the case and bearings as sent back
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after cleaning and being blown through with dry nitrogen.
Image


the re- cond'd crankshaft
Image
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Re: my new engine build

Postby caveman » Sat Feb 22, 2014 7:39 pm

the time came to start building the crankshaft after wilbore engineering had inserted new small end bearings and honed them to the gudgeon pins supplied with the new barrels and pistons.

Image

(sorry for the fuzzy pic)
following directions in my build manual I heated the crank gear in veg oil till their was whisps of grey smoke coming from the oil ( I used a catering sized bean tin as last time I did this I ruined a saucepan and had to buy a new one lol)

when it was hot enough the crank gears and spacers were installed!! ---- SUCCESS!!!! --------or so I thought

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I couldn't get the retaining circlip on. I thought it was due to my circlip pliers so I headed over to Carl's workshop where he offered to help fit the clip with his special pliers......


he noticed that I had put the first crank gear on upside down in the panic to get the gear on before it cools down - this prevented it seating down and thus didn't give the circlip enough space to seat - handy really as I wouldn't have realised until later in the build when trying to mesh the cam and crank gears.



he removed my efforts and corrected the order so all is now well - Thankyou Carl - lesson learned

so back at the ranch I needed to replace the big end bearings on the con rods


after doing so I lubed up both the crank journals and the bearing faces. I installed and torqued the conrods to the figures given in my manual
Image


I am now waiting for my cam bearings to turn up - I am using double thrust as its a little extra protection for not much extra
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Re: my new engine build

Postby caveman » Fri Feb 28, 2014 7:28 pm

so the dual thrust cam bearings have turned up , and I have realised that I need to block off the oil pump - something carl has agreed to help me with - which is very kind of him im sure I couldn't do this without his knowledge 8) should be pushing on soon
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Re: my new engine build

Postby TawCottage » Fri Feb 28, 2014 9:48 pm

Keep the pictures coming Matt.......nice thread 8)

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Re: my new engine build

Postby caveman » Sat Mar 01, 2014 9:04 pm

so today I have got on quite well with the aid of Carl

I popped over to see Carl and he helped me by blocking off the oil outlet of the oil pump he did a great job and im glad it was him that did it as id prob have cross threaded it lol


Image


next was to build up the short block!!

I inserted the cam bearings twice - once I even got them correct!!?? lol

then the crank shaft assembly and the camshaft was inserted not forgetting the cam shaft plug.
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the cam lobes were coated in can grease (not in pic ) as were the heavy duty lifters and the bearings were all lubed with engine assembly lube



Image


The case was sealed with case sealent and then all the bolts were torqued to factory settings in the correct order leaving me with a short block to hopefully be proud of!! lol


I have put the head bolts into soak so they should be clean for tomorrow when ill install all that I can until the heads come back form the machine shop


thanks definatly go to Carl for all his help thus far 8)
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Re: my new engine build

Postby caveman » Sat Mar 01, 2014 9:05 pm

im amazed to say that it still turns over too lol :lol:
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Re: my new engine build

Postby funkyfreakapotomus » Sat Mar 01, 2014 11:46 pm

Loving seeing this!!
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Re: my new engine build

Postby caveman » Sun Mar 02, 2014 4:48 pm

cheers buddy



right so another day so back in the garage.....



so I needed to set the end float I did this without the oil seal in as the book said and set it to within limits (close to min settings but not on it) so that's all cool it required a few shims to be exchanged but nothing too worrying all was checked with a dial gauge - quite a simple idea really pull the flywheel out as far as it goes and set the gauge then push it in and measure the travel - using shims set this within limits - recheck - done! Image

Image


installing the crankshaft oil seal
Image

then disassemble fit oil seal in case and flywheel and torque to 220 ft lbs ( ny torque wrench doesn't go any higher so I hope that's ok? I did use Loctite ) I then rechecked the end float and all was well

also I checked that the engine still turned over ok - it does - Phew
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