DDK - Die Deutschen Klassiker

Spent a day doing a few "nice to do's" while I wait for engine parts .I was doing a little lathe work for a fellow DDK member but got distracted by this.......been meaning to sort it to stop the Bloxworth massive setting off my extinguisher and I had the last decal to fit. So I moulded a grp cover from a steel original filler cap and used a couple of dzus fastners and some foam tape and hey presto.. The decal isn't quite perfect and the fit won't suit a concours queen but I like it.



then I fitted my tent pole bonnet stay.



and finished the turning job

Maybe a bit more tommorow.

andy

A bit of detail on my fuel manifold with leakoff back to tank through an old motorcycle carb mainjet. This is what micro light builders do apparently so must be good...




I've been assembling the engine space stuff so may take a few snaps later but might wait to resolve the coil stuff before doing so.

Andy

Some bottom end engine progress to report its going to be 2.8 with 10.5 :1 JE's twin plug and s cams all the case work and a full 0.25 g balance,














Oil catch tank , held in with VW Golf Mk4 rubber strap and bracket..she won't notice its missing




ttfn

Looking v good!
I'll be doing my 3.2 very soon after a rod let go yesterday...
Are you using stock rod bolts in your build? (or ARP parts)
Graham

Hi Graham, stock rod bolts for me.

andy

haasad wrote: Oil catch tank , held in with VW Golf Mk4 rubber strap and bracket..she won't notice its missing



ttfn

Engine looking fab.

Oil catch tank fits a treat too. Glad it arrived safe and sound.

Kind Regards

Off to Langcourts today with my old cylinders and a new set of 10.5:1, 92mm JE's. Hoping they wil work some magic with the overbore and new nickasil.....geting close to having an engine now.

So exited

Andy

Bottom end boxed up,




Cylinders on way




A problem was revealed when prepping the cylinders for boring, they had corroded around the skirts possibly due to poor storage or contact with acids somehow ? There was no solid metal left in places even though they looked like once bored the corroded areas would be removed. Luckily I had another set of 90mm mahle alusil ones which have proven fine for transformation into 92 mm mahle / langcourt nickasil.

coming together now.

andy

Some shiny bits from Langcourts and JE.




JE's are the usual good quality but I was really impressed with Langcourt. The cylinders I sent that were unusable had all been blasted which took time. They didn't charge me...and the good set including a weld repair to the sealing ring area prior to re maching boring to 92 mm and new nickasil look absolutely perfect . All the bores are to perfect spec

Just got to check the cylinder heights and gap the rings and it can go together up to the heads.

I'm green with envy!
Look very good.
Looking forward to your tutorial on cam timing!

haasad wrote:Some shiny bits from Langcourts and JE.




JE's are the usual good quality but I was really impressed with Langcourt. The cylinders I sent that were unusable had all been blasted which took time. They didn't charge me...and the good set including a weld repair to the sealing ring area prior to re maching boring to 92 mm and new nickasil look absolutely perfect . All the bores are to perfect spec

Just got to check the cylinder heights and gap the rings and it can go together up to the heads.

Andy,

What was the cost of boring out the cylinder and applying the Nikasil? PM me if you like.

Cheers
JOn

DustyM wrote: Andy,

What was the cost of boring out the cylinder and applying the Nikasil? PM me if you like.

Cheers
JOn

Or you could tell us all

OK it was just over 1k for all the cylinder work

andy

Todays efforts.
Checking valve stem free length. after seat cutting and lapping . I need to remove 0.4 mm from the stem on each to maintain geometry and build tolerance.




Ring gapping (0.015 each at D2 for all) interestingly the onl ones needing adjustment were the top rings 2nd comp and oils all fine out of the box. Note how to gap all the oil control scrapers together as a stack at D2 They are so flexy its hard to check this any other way.




Fitting pistons into cylinders, clean and oily gently does it!








Deck height checks tomorrow if I can keep patient with those horrible pin retaining clips, what ever is wrong with proper circlips

Todays efforts.
Checking valve stem free length. after seat cutting and lapping . I need to remove 0.4 mm from the stem on each to maintain geometry and build tolerance.




Ring gapping (0.015 each at D2 for all) interestingly the onl ones needing adjustment were the top rings 2nd comp and oils all fine out of the box. Note how to gap all the oil control scrapers together as a stack at D2 They are so flexy its hard to check this any other way.




Fitting pistons into cylinders, clean and oily gently does it!








Deck height checks tomorrow if I can keep patient with those horrible pin retaining clips, what ever is wrong with proper circlips