Thanks Gary, what's the saying, take care of the pennies and they look after the pounds.........or something along those lines.
Hugo I have disassembled and rebuilt the engine when I first got it to solve some major oil leeks, but
taking care in the detailed specs I haven't. I've always wanted to do it since owning beetles when I was younger.
Neil I used the Plastiguage method as a cheap alternative to expensive micrometers.
The Neutek cam leaflet says to run it for 20 mins or so at 2 or 3 thousand rpm for intial break in.
I wont worry about dyno's just so long as its run in healthy manner for now. Fine tuning is way off in my mind still.
So rookie procedures equals more mistakes.
I put the crank in the case, put the cam in to feel how smoothly the mesh together and binding in 4 positions .
Looking at the cam wheel it binds at north south east and west.
So I carefully file the cam gear until there was no more binding......But now I had a load of backlash. POOOOO
Looking back over my progress I realised the when i heated the steel gear to put on the crank It hadn't dropped on like I expected it
would do. So I knocked it down with a socket extension and hammer.
Where I have hammered it, it has deformed the edges of the gear. More embarrassment.
20230523_124544 by
karlhash, on Flickr
So I went down to PRS and Paul Smith who was wonderful as ever, looked after me supplying a new set of straight cut gears, pushrod tubes and some sundries.
As I was getting a little excited about the prospect of nearing completion I thought about the poor battery Ive left for so long unattended.
I had thought that it may have died and may not be able to be recharged but I had a shock when I took it out.
It had massive cracks in the top. Apparently the cells can swell and cause this. So new battery needed then.
20230524_192110 by
karlhash, on Flickr
Whilst at the front of the car I had noticed some brake fluid in places so I checked the reservoir ....... empty!
I had rebuilt the master cylinder before but as this has happened and with safety in mind I bought a dual circuit master cylinder to take it's place.
And because the brake fluid had leaked , the pedal box was wet and rusty and flaky. So I took those out to paint and clean up.
20230527_114515 by
karlhash, on Flickr
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karlhash, on Flickr
The toe boards were de laminating so glued those together.
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karlhash, on Flickr
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karlhash, on Flickr
Getting a little side tracked, because the front area has never really been clean I took the tank out to lightly sand and T cut but mainly to put in new felt underneath and around the straps.
20230605_182817 by
karlhash, on Flickr
20230608_172327 by
karlhash, on Flickr
For the new master cylinder I made connections for the wires because the new brake switch has spade terminals and the old original wires have circular screw fittings that I didn't want to chop off,
returning to original and all that. I rubber booted the lot in an attempt to keep the water out.
20230610_132749 by
karlhash, on Flickr
Put some rubber sleeve on the old lines for a bit of added security as sparks and fuel don't mix well
20230610_181241 by
karlhash, on Flickr
Rubber boot and grommet for fuel line had all corroded so replaced those also.
20230611_155701 by
karlhash, on Flickr
Progress report for now done , may be a while until the next as I'm in for hand surgery on Duputrens contracture, which progressively pulls your fingers closed. Having my little finger done.
All the best
Karl