The barons restoration. 1970 fasty.

nidge · Post by **nidge** » 8th April 2008 - 9:02pm

BTJustice wrote:

If you have the part number and a set of the long bolts for fitting the oil cooler please let me know.

i'm sure i got some from B&Q when i lost one

BTJustice · Post by **BTJustice** » 8th April 2008 - 9:15pm

Yea, I was thinking about using threaded rod and making them up but Im really stuck for the plug.

BTJustice · Post by **BTJustice** » 12th April 2008 - 3:11pm

I spent yesterday afternoon on the engine and took about 3 more steps backwards.

I started with this;

and all was going well. I got the studs in for the oil filler, cleaned up a set of head studs and had a brand new oil pump soaking on oil before fitting.

Unfortunately by the end of the day the case was open again because of this;

So that'll be the cam shaft shafted.

My own fault but. I didnt know there were 2 depths of oil pump so I was bolting a deep pump onto a shallow cam shaft and destroyed the shaft AND the pump. Guess I will be down at GS&F Monday for new ones.

BTJustice · Post by **BTJustice** » 15th April 2008 - 8:22pm

I got my camshaft and 2'nd pump this afternoon from GS&F. All together the 2 pumps and new cam have cost me just under £100, expensive mistake.

So with the new parts it meant I could re-assemble the case, fit the oil pump and threadlock the head studs in place.

Going to continue the re-assembly through the week and hopefully run some tests on it by the weekend.

Dave.

BTJustice · Post by **BTJustice** » 16th April 2008 - 8:03pm

Another 2 hours tinkering today sees the oil cooler on and cylinders 3 and 4 on with the head loosly bolted in place. I will torque the head studs once the other side is assembled as its supposed to be better to do them in matching pairs side to side so as not to stress the case.

Dave.

BTJustice · Post by **BTJustice** » 17th April 2008 - 7:20pm

Another 2 hours spent on the engine. Both cylinder heads on and torqued up, push rods in, rocker gear on, distributor drive and distributor fitted, fuel pump rod, pedestal and push rod in, oil filler kneck fitted and oil breather pedestal on.

Dave

BTJustice · Post by **BTJustice** » 21st April 2008 - 7:15pm

Couple more updates after the weekend.

I got a wee bit of time spent on the engine over the weekend.

With heads assembled and the engine sealed I filled it with some oil to chech for leaks. I fitted an old bell housing and a starter motor along with an oil pressure guage to see if I could get it primed and showing pressure.

I couldnt get the guage to show pressure so after taking a bit of advice on VZi I decided it wasnt spinning fast enough on the starter and the only way to really test it is to go for it and finish assembly.

It was spinning nice and freely so thats a good sign.

So with a bit more time spent I got the nos heat exchangers I picked up cleaned, painted and wrapped in their jackets before fitting.

I also made a phone call to a local trimmer recommended by one of my local club members.

I am so fed up with it now being 7 weeks since I was sent the wrong back seat cover from Karmann Konnection and TMI (3 months since first order) and with no sign of resolution on their part I could no longer risk not having a back seat in time for show season.

So Ricky the trimmer is away with the new cover and the old cover and will adapt the new cover to fit properly so hopefully the interior will be finished soon.

Im also still waiting for my bumpers. That will be 7 weeks this Friday since I was told they would be no longer than 3 weeks, talk about frustrating.

Dave.

nidge · Post by **nidge** » 21st April 2008 - 9:32pm

you'll have to cut those oil pump studs down

Have you blanked off the oil pressure switch on the side of the block?

BTJustice · Post by **BTJustice** » 21st April 2008 - 9:37pm

Cheers Nidge, the pump studs were going to get the chop but I wanted to wait until the pump was in its final position just incase the threads get damaged.
And the old oil pressure switch hole is blanked off, would have made quite a mess if I hadnt and then started the engine

.

BTJustice · Post by **BTJustice** » 27th April 2008 - 6:44pm

Its been a busy weekend on the car and starting to feel like Im getting somewhere.
I couldnt go any further until I found a rear mounting bar for the engine. The engine I stripped was from a swing axle car so had a different mount.
Huge thanks to Mikelkca who came up trumps and not only found me a bar but dropped it off in Glasgow for me
On Saturday I got work done on the engine. The fan housing and fan are on, took a while to get the fan centred but working now without rubbing. I also got the tins assembled around cylinders 3 and 4.

Glad I got the tins coated now as I think it looks great.

I got a call this morning from Ricky the trimmer to say my rear seat cover was done so today I have spent the afternoon finishing off my interior.

Cover only cost £20 to have re-done so Im well happy I gave him a call.

Hope to get more done through the week, maybe get the engine finished off but I want to MOT the car before doing the engine swap so might do that through the week as well.

Dave.

BTJustice · Post by **BTJustice** » 28th April 2008 - 9:37pm

More progress today.

Tinware complete, dynamo on, carb linkage on, ballance pipe support on and then the bit that I have been looking forward to for months, exhaust on.

I was going to wat and put the exhaust on once the engine was in the car incase I scratched the ceramic coating but Im glad I did it now as it was a difficult fit and I snapped a stud off the head. It would have been a real pain if I had done that with it in the car.

The car is going for an MOT at the end of the week and Im thinking if the weather is good the swap will happen Sunday and Monday.

I need to rob the carbs off the old engine but thats it so if it goes tits up it wont be too hard to swap back but I dont want to think about that.

Dave.

BTJustice · Post by **BTJustice** » 2nd May 2008 - 8:24pm

Well I took the car down for an MOT so that there was no question of it being mid engine swap at MOT time and the test lapsing.
As expected it passed. The amount of time I have spent under, in and round the car recently I think I would have cried if it had failed.
So the plan this weekend, as its a holiday weekend is to try and get the engine in and running but there is one problem.
If you look at the pics of the engine build you will see I have been doing it on a workmate.
So how the hell am I going to lift it down by myself?
One of the small details I need to address but I will let you know how I do it and how it goes.
Dave.

BTJustice · Post by **BTJustice** » 3rd May 2008 - 7:56pm

I have managed to rope a mate into giving me a hand lifting the engine off the stand tomorrow so today I pulled the old engine from the car and swapped over the coil, carbs, ballance pipe and the last of the tinware.

Might as well be heavy if Im getting a help

BTJustice · Post by **BTJustice** » 4th May 2008 - 7:00pm

I have spent the day working on the car and good news, the engine is in;

The bad news is that allthough it is running there seems to be very little oil pressure.

I dont know at the moment whats wrong. The oil light comes on at idle and given a bit of gas the max pressure I got from it was 1.5bar so something aint right.
Thinking it might be the pressure relief valve I opened it up to have a look and also opened a scrap case to compare what was in each.

The spring on the left came from the scrap engines relief valve and the spring on the right came from my new engine.

Thinking that migt be the problem I fitted the longer spring in my new engine but no change....... Still low pressure.#

Im not quite sure where to look for a solution at this point.

Dave

Post by **purplepeter** » 5th May 2008 - 9:40am

Dave,Not sure if you want the answer on here or vzi..but the two springs youve shown are two different things-one is oil pressure relief valve,t'other is bypass valve.generally,its not possible to get the wrong spring in the wrong hole,especially if youre upside down under the car!

check carefully-your case may or may not have two valves,but you need to check

BTJustice · Post by **BTJustice** » 5th May 2008 - 10:45am

Cheers PP, I had remembered the relief valve was almost an afterthought as I was packing up one night and thinking at the time the spring was so long it didnt seem right so I stuck the short one in at the time.
Yesterday when I wasnt getting pressure this was the first place I looked and when I opened an old case and saw the long spring was the one to use I swapped them over but still no joy.
Im going to open up the valve again and check it some more but in the hope that I can rectiy the problem without stripping it down again.

Post by **purplepeter** » 5th May 2008 - 11:13am

I'd be tempted to try an oil change!
If youre certain its a single relief case..you know theres a difference in the sump strainers dont you?-not entirely thunk through this,and cant quite see it causing low pressure,but thought i'd throw the idea up anyways

how much & what kind of assembly lube did you use?-on bearings etc?

wont be online til tonight,so dont expect any further pearls today!

BTJustice · Post by **BTJustice** » 5th May 2008 - 8:32pm

Problem seems to be solved.

I took the relief plunger back out and cleaned up the bore with some sandpaper taped to a drill bit.

When I replaced the plunger it sat a good half inch further in and when I turned the engine over I got good pressure (2 bar at idle settling to 1bar after about 5 minutes and picking up to 5 bar when revved).

I took it a run round the block and it drives bloody lovely.

The only problem with gaining pressure was it showed up a weep in the oil pump face plate so the engine came out again, stripped it down and sealed up the pump.

Its all back in and working fine with no leaks.

Im going to re-do my rocker clearances tomorrow as it sounds a bit tappy then go for a longer test run allbeing well.

Cheers for your help PP,
Dave.

Post by **Editor** » 5th May 2008 - 9:16pm

Are you sure it was 5 bar when revved (75psi) ?
Published figure when pressure relief operates is 42psi. If that's not working properly you may split the oil cooler - messy and potentially an engine killer.

BTJustice · Post by **BTJustice** » 5th May 2008 - 9:46pm

I will double check tomorrow but it was there or there abouts unless Im reading my guage wrong.

Looking back at my you tube video;
http://uk.youtube.com/watch?v=V_uARzbbzWQ
3 and 5 bar are pretty close on my guage so probabply wont have been as high as 5 but was deffinately over 3.

Post by **Editor** » 6th May 2008 - 1:10am

Your old engine on the video behaved perfectly - going up to 3 bar when the throttle was blipped.

If you've the two pistons, the front one (away from the oil pump area) has the shorter spring and opens to limit the pressure and protect the cooler. The one at the rear near the oil pump has the longer spring and diverts oil away from the cooler when warming up (and therefore thicker oil).

Pre-70 there was only the one valve that was near the oil pump and was double acting.

BTJustice · Post by **BTJustice** » 6th May 2008 - 7:52pm

Tonight is not a good night. Mojo is at an all time low.

What started as a bit low oil pressure turned into no oil pressure after the test run so looks like strip down time, Im so pissed off right now........Anybody want to buy a fasty?

On the plus side I did run it long enough to make a comparison video between the old exhaust and the new exhaust (it sounds better in life but you get the idea).

So Im off to see how expensive another re-build will be and if I can do it in time for the Scottish VW owners show in 2 weeks at Biggar.

Dave.

BTJustice · Post by **BTJustice** » 7th May 2008 - 11:01pm

My thought today was that there was a possibility I had crushed the oil cooler seals so to make sure I removed all the tinware on the left of the engine and the cooler to check.

My thought today was that there was a possibility I had crushed the oil cooler seals so to make sure I removed all the tinware on the left of the engine to check.

When I re-assembled the engine it was pretty much the same but the pressure was settling at 0.5 bar with no "light of impending doom" coming on on the dash so I decided what the hell, take it to clubnight and if it dies on the way im no worse off.

Oil pressure didnt drop less than the 0.5 bar appart from when I got stuck in traffic pointing down hill.

I still want to do some more to try and increase pressure so Im going to try and get hold of the later pressure relief valve and change the oil to a 15-40 mineral as opposed to the 10-40 synthetic thats in just now.

Hopefully this will help but I have decided to try and persevere with this engine rather than chuck it and start again.

Dave

Post by **Editor** » 8th May 2008 - 12:08am

There are specific issues with oil cooler seals, but I've not done the job so don't recall all the details.

I'll see if I can find the e-mails about it and forward them to you. For example, there's something about an early '70s case that you can't get a suitable oil pump for. Something to do with outlets not lining up.

PS Oil seal and oil pump e-mails on their way.

BTJustice · Post by **BTJustice** » 8th May 2008 - 1:12pm

I got the e-mails Dave and there is a huge amount of usefull detail in them.

Reading them through it seems I have bumbled and stumbled my way to the correct combination.

Single release valve case, no part number on my cooler so its an earlier one and I just fitted washers to space the cooler off the case so completely by accident I seem to have matching parts.

Cheers again for sending me that,

Dave.