DDK - Die Deutschen Klassiker

Winston , yes, exactly that. It stops the plain Cork gaskets deforming and slipping out of place.

Karl.

Well I thought I was doing well. starting to see the end in near sight.
I put the inlet manifolds on, matching up the gaskets and a bit of fine tuning

20240319_163404 by karlhash, on Flickr

20240320_160139 by karlhash, on Flickr

And then I noticed the pushrod tube seals were weeping. this is before I've put all the oil in it. so if some is weeping with just a little in, what will happen when I fire it up. The case bolt I had trouble with was also weeping.
So I took a deep breath and took it all apart, well as much as was needed.
I took the centre case bolt out, only needing to remove one barrel and put new seals on it and a dollop of Hylomar blue.
Then I looked at the pushrod tubes and realised that their end washers were a little bit big for my case and heads.
I tried to grind one down but that took forever. Luckily I spoke to my farther in law who donated my hobby lathe and told me the chuck jaws on that would hold the washers from the inner diameter.
So I was able to turn them all down by 1mm.

20240321_173526 by karlhash, on Flickr

just too big
20240322_125719 by karlhash, on Flickr

Turning the washers individually
20240324_133127 by karlhash, on Flickr

Smaller washers, which also made it easier re fitting the heads this time.
20240324_183448 by karlhash, on Flickr

Thanks
Karl

This is a lesson for all of us. Good work

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I always wondered why people charge so much to build these engines. Evidently it's machining all the washers...

Nice work

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One of the benefits of a slow(er) build - problems like this become apparent before you start the engine.

A satisfying, if time-consuming, solution - well done Karl !

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Well done on all this work you have done very well indeed.

Roy

Well done on all this work you have done very well indeed.

Roy

Thanks guys,
all this time and work , just because I wanted to clean up the engine and stop some oil drips in lock down!

Karl

Hello, time for a catch up. Trying tapatalk for the first time, as I've run out of space with Flickr.
So, oil cooler on, manifolds and phenolic blocks on. I dragged out the fan shroud wich i had no intention of working on, but it looked a bit rusty in spots . So a quick sand and touch up of paint. I cleaned the fan also, but wanted to get a new welded fan, so didn't clean too much. At least i wouldn't blow crap through the oil cooler now. Then the heater flapper boxes needed stripping, because I didn't want oily fumes blown into the cabin when I hook them up. That took longer than I wanted it to. I bought a new welded fan for a VW from Stateside tuning, knowing it would be wider than my original. I thought i could space it out with a cork washer on the fan housing but it was putting my fan belt pulley way out of alignment. My old fan is in good condition, and Vic Skirmants, the seasoned racer says he doesn't weld his fans, so I'm sure mine will be fine for now. I can always get it welded later on, for added security.
I'll post more soon.
Thanks
Karl.

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