The Cal-look Lounge

Because I got some plans for my '64 bug this year, I thought I open a topic.

It all started with this bug I bought when I was 19, (20 years old now :P).

(http://www.keversite.nl/fotoalbum/fotos/63946.jpg)

Pretty much a stock bug, except for the Flat 4 BRM's. It was also converted to 12volt and has a Mexican 1200 engine in the back.

(http://www.keversite.nl/fotoalbum/fotos/63947.jpg)

Interior was also stock and very old.

Than I got on the wrong track, I bougt a foglight and a roofrack  :'( I won't post a photo of that fase :P.

This is how the bug looks now, photo was taken on the way back from Das Drag Day #5. What a great event! The bug is lowered with a CB Perf. front axle, it also has an electronic 1-2-3 Ignition.

(http://www.keversite.nl/fotoalbum/fotos/63638.jpg)

This winter I ordered a new interior from TMI and fitted it with help of my dad. New carpet, seats and doorpanels. This is how it looks now. I'm very proud with the result.

(http://www.keversite.nl/fotoalbum/fotos/63639.jpg)

(http://www.keversite.nl/fotoalbum/fotos/63640.jpg)

So what are my plans for this year:

* Autometer monster tacho
* Disc brakes in the front
* CSP-Shifter
* EU rear bumper
* 205/70 tires
* Cool exhaust for my 1200 with a fatboy muffler
* Starting on a 1776/1915 engine(winter 2008)

Who knows a good 205/70 tire? And what make of front disc brakes?

nice car & love the interior upholstery
why don't you put another tach like a vdo or smith , too many auto meter for me IMHO  ;)

nice car Jesse.  Interior looks stunning!   :P

Goodyear makes nice 205/70 tires... Eagles

I have a pair for my car, looks great. Fairly cheap too if i remember correctly.

With the 1200 I'd go for a smaller tyre and muffler - a 185/70 would be ideal, and a 4 into 1 header with a little glasspack (painted white!) with a chrome tip would look spot on for early Cal Look!  ;)

i agree neil

that's what i think as well  ;D
but it's your call jesse  ;)

your interior looks tip top as well.

and you might wanna reconsider going with a 1679cc - that's gotta be the coolest displacement around.

Thanks guys!

@ Diederick, 1679cc - very cool yes, but will it make enough horsepower  8)

About the tires, I'm going for the 205/70's. It will only be one year with the 1200.

About the front disc brakes, does anybody have experience with the kit from A.C. Industries?

Not the whole kit, but I used their rotors and they were nicely done.

--louis

Two weeks ago I fitted the rear wheels with Bridgestone 205/70 tires.

(http://www.cal-look.nl/gallery/albums/userpics/10011/PICT0001~1.JPG)

I also got tipped by a friend about a 'tuned' engine in somebody's garage nearby. Will have a look at it very soon. Do you guys have some tips on where to look at when buying an engine?

a 1679cc engine is alot of fun and will provide enough hp.
Depends on how you build it of course and for what purpose.

A well build 1679 can beat any 1776 or so engine.Its all in the combo
of engine and gearbox etc and of course money counts. ;D

Just got a reply from the guy with the engine, he is going to use it in his own bug  :'(

For brakes its either CB, Airkewld, or CSP.

Guys, what are your opinions about an Auto Linea case? A shop here in the Netherlands sells them for 500 euros. It than clearenced for a 82mm crank, bored for 94mm or 90.5mm cilinders and ready for full flow. Will that be a better investment than buying a second hand AS41 case and have it machined (don't know what machining costs?).

Plan is to go for a 1915 or 2110. Or is that to much for a first time engine build?

i think that case is just fine. and starting with a fresh case gives you a lot better start position than a used case (not knowing what to expect of it)
and as i said, w.r.t. the current $ rate you can get any case shipped to NL for even less.
but the most important thing is if anyone would recommend building either a max displacement stock stroke engine (like i'm doing) or a conservative large stroke engine (funny comparison vs 1915cc) engine. and i can't give a rightful answer to that yet...

I asked John Maher the same thing back in 1998 or so. I was looking for advice on something streetable and capable of mid-to-low 14's. John asked what parts I'd got already (basically only a set of 40x35.5 heads cut for 90.5's and a pair of 40IDF's) which really narrowed it down to a lazy 2007 or a more highly strung 1776. Basically the conclusion was that the bigger the displacement, the less work it has to do to run a set number. A 2332 should run easy 12's and be relatively low stressed, wheras a 1776 in the 12's is possible but will be a more stressed motor.

Of course, I decided to build neiother motor and a few years later ended up with an IDA'd 2180! ;D

This Sunday I bought an 1300AR motor.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC00189.JPG)

It is really dirty but internally it looks good. It's an AS21 case. After a lot of talking and discussing I'm going for the 1915cc engine. Based around a DPR 69 welded crank, Engle w-125 camshaft, and 40x35mm heads, and a lot of other stuff :P. Seems like i'm going to have to save a lot of money.

Yesterday I split the case, it all looks good inside. Soon I will go to a machine shop to have it drilled for 94mm cilinders and tapped for full flow.

This is the setup I have come up with.

AS21 Case
DPR 69mm welded C/W
Stock rods
Engle W-125
Mahle 94mm cilinders&pistons
Gene berg lifters
Gene berg pushrods
40x35.5 heads (SCAT, CB, Steve Timms??)
Gene Berg HD rocker shafts
Stock rockers
26mm oilpump
Weber 40 IDF or Dell'orto 40mm (looking for an old Alfa 33 :P)
1-2-3 ignition
12lbs flywheel
Merged header + empi phatboy

Any comments guys?

About using the stock rods, in the aircooled vw interchange manual of Keith Seume it says that stock rods are great for a street engine, what could I do to improve them? What bolts etc.?

Sounds like a really nice combo.

If the case is good,then use it,but check for cracks.Does it have case savers?

I prefer the new case.

You will have problems with Alfa carbs if you don't get the right ones.I suggest Dellorto 40,and get all your jets and parts from CB Performance or from Dellorto.co.uk.The first important thing to check when you get the ex-alfa carbs,if the throttleshaft moves freely.If it does,than they shouel have  future.

I have repaired and rebuild few sets of these carbs,and they are not too bad.Be sure to get non leaking floats.

Yes it has case savers with M8 studs. When I find a set of carbs the will be rebuilt and ultrasoon cleaned.

I think is better to make a new line on your as21 case , so you can start with good material .

Look for the rods , you can have good ones ( flat4 , CB etc..)  , not expensive .

Don't use Alfa carbs , always problem in pespective !! maybe try to find  44 idf .

why not use DRLA 40??? Very good carbs, I restored my pair and they work really well. Just aded CB ubdate kit nad its mint (not so many trubble with jetting...), they don't need that but jet doctor of CB is a very good idea.
As I heard DRLA's are the most sofiscicated carbs on the marcket (those days).

@ Greentom, well I'm going to look for some secondhand carbs from old Alfa 33's. They were fitted with Weber 40 IDF or Dell'Orto 40 DRLA. So it depends on what I find.

@ Fred, thanks! 1915cc should be a great engine and the most bang for buck.

I splitted the case and everything looks good, no cracks etc. By the way the American guys, are there any cool VW shops located in New York? Because I'm going to New York with school in May.

Jesse, do yourself a Big favour. get a New Case.

 A case isn't that heavy and with the current exchange rate it might be a good idea to order one abroad.
 Lowbugget sells machined cases for $499,- which is +- €315,-. We could order our cases together to save $€$€...
 (I think washing/checking/alignboring/machining that case will cost well over €350,- won't it?)
 

And still have low oil pressure, crap floating around, etc.

I think you need to do most of that with a new case as well...

I'd prefer a decent AR case over a new auto-linea case any time. New mag cases are not always any better in quality these days either...

Thought of giving you guys an update. Bought a turbo muffler and a 1 1/2 inch header at EBI2. Still debating on the engine choice, 1776 vs 1915 and which cam. The rest of the setup I got pretty worked out.

DPR C/W
Stock rods
SCAT Mini-D heads
GB pushrods
GB lifters
Stock rocker arms with HD shaft
40 DRLA's for now and saving for 48 IDA's.
1 1/2 inch header
1-2-3 ignition

What do you guys think? 1914 of 1776? With a stock 1200 gearbox and what cam? Was thinking of a Engle W120 of W125.

Thanks!

(http://www.cal-look.nl/gallery/albums/userpics/10013/Exhaust_001.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Exhaust_002.jpg)

There's no replacement for displacement!   ;D

my 2c awful sound of that muffler :( it sounds like you would stick a plastick plate to e bicycle wheel frame next to the wheel... :) hery sharp noise enoying sound. especially ather 200-300km :)

Well I like the sound :)

Just got news from the machine shop. My old case is to bad to use :(, needs line-boring etc. So I have to look for a new case, thinking of getting it out of the USA, which shops are good there?

I'm getting my DPR crank this week :).

If you plan to order a new case from the USA,I strongly reccomend  Brothers VW Machine shop in Ontario California.

I ordered my case from them for my 2276,and they did the beautifull job sleeving the lifter bores,decking and full-flowing the case.And great prices too.

I think that cases start at $400 + additional machining costs.

Send an e-mail and talk to Jacob or Renato: brothersmachine@hotmail.com

http://www.thesamba.com/vw/classifieds/detail.php?id=454587 (http://www.thesamba.com/vw/classifieds/detail.php?id=454587)

http://www.brothersvwmachineshop.com/contact.htm (http://www.brothersvwmachineshop.com/contact.htm)

Great guys and great service.

Thanks I already looked at their site, nice prices. I'm not sure which options I should take for the 1915.

I'm sure on these:

Bore Engine Case to 90.5mm / 94mm Pistons = $45.00
Deck Engine Case = $35.00
Drill / Tap / Plug Oil Galleries = $75.00
Full Flow (Drill and Tap Engine Case) = $30.00

But are these also necessary?

Lower Lifter Bosses = $40.00
Sand Seal Case w/Seal = $35.00
Shuffle Pin Center Main = $85.00
Sleeve Lifter Bores (Silicone Bronze) = $125.00
Sleeve Lifter Bores w/Groove (Silicone Bronze) = $150.00

Thanks!

 

If you are buying a new crank, why not go for a 76mm, or even 78mm, it wont cost much more than a good 69mm. Free cc's ;D

If you have a OEM case yes, but I dont know if this is neccesery with after market cases.

You lower the lifter bores when you have a cam with more lift, usually even more so when it still has a decent base circle (ie with smaller strokes the say up to about 78mm depending on rod big end diameter). The work is usually/best done with the lifters and the cam you will use to be present at the machine shop, so they can give you just about enough clearence. Not too much clearence as your lifter should be supported by its bore as far and as much as possible.
Hope you see the picture of this before you  ;)

Thanks Walter  :)

With Jesse running a stock stroke 69 c/w crank with w120 or w125 cam it is not neccesary to lower the lifter bores even with the bulky stock rods. 8)

Thanks guys for your answers, but now I have two different answers :P. I'm running a DPR 69mm C/W with CB Perf Uni-Tech HD plus rods with a Engle 120 (or equivalent from Webcam).

Anyone else has good experience with Brothers VW?

Brothers is a machine shop and they are good i heard 8)

Go for the 1914cc and don't look back 8)

If you go with an Engle W120,with a good set of ported 40x35.5 heads it should be a nice combo.

If you would like to go with an Engle w-125 I think you should sleeve the lifter to have a peace.

Trust me,they are one if the best machine shops out there,they can do any work you can imagine.Tey also doweled my 82mm crank with 11/32 dowels,balanced it,and the flywheel and pressure plate

Thanks for your replies, what about decking the case, is that needed with a new case?

I would do it in either way

It maybe isn't neccesary when bored for 90.5,but when it is bored for 94mm cylinders you only have a very thin cylinder seating area withouth decking

Update:

I got new front tires, 135r15 from toyo, also adjusted the front a little bit lower. I love the stance now.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DVK-004.jpg)

I also got my crank from DPR, great peace of steel :D.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DPR_001.jpg)

Also bought some heads from Dokke/DFL, will get them next week. The heads are 041's with 39 x 35.5 valves with Remmele valve springs and some porting done by Remmele. Because of this I will build a 1776. Parts are coming in slowly it's hard as a student :P

You could go 1835... ;)

Got my heads last weekend. Really pleased with them :)

(http://www.cal-look.nl/gallery/albums/userpics/10013/DDD_112.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/DDD_115.jpg)

Get Rid of the Aluminum Spring Retainers there Bad News put some Chrome Moly Ones On

i'm sure he will and put dual springs on it as well  ;)

stance is bang on now jesse ;)

Nope I will stay with these single springs, keeping the valve train light.

Why should I change the retainers for chro-mo? These retainers are made out of aircraft alu by Remmele. I think they are stronger than 18 dollar chro-mo's from CB?  ???


@67worshipper, thanks! I'm really pleased with the look now.

impressive  ;)

Aluminum Wears I have seen to Many Valve's Pull threw and Drop A Valve I would use stock ones over aluminum but Recomend Chrome Moly Retainers

Condolences to your heads.

Strange post. Why?  ???

Because?

Alu Retainers, pm'd you back. Like Shubee posted, i rather go for stock then that crap. Go titanium, and sleep well. ;D

Ok guys, I'm about to order my clutch setup. Going for a Kennedy Racing Stage 1 but I don't know which disc out should use? Primarily street use.

What's the difference between these?

http://www.vwspeedshop.com/shop/product.php?productid=1033&cat=285&page=1

and

http://www.vwspeedshop.com/shop/product.php?productid=1035&cat=285&page=1

it's for a 1915, K8, IDA.

This is all very interesting, Im in the same boat as you, shoe string student lol

Just wondering how much your new case was? As i was gonna use a old 1200 case with not many miles on it for a 2276 or 2.1 project? ???

cheers

The case was 540 euros I ordered it at John Maher, I had an old case at first but I was just as expensive to get that one line bored etc as a new case.

Some pics.

(http://www.cal-look.nl/gallery/albums/userpics/10013/AS41-002.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/AS41-001.jpg)

This week I will order a lot of the smaller parts, cam, lifters, oil pump etc.

Cool Jesse !  Case looks nice :)
Have you orderred the smaller parts at Kaagkevers with the groupbuy ?

Greetz

I ordered SCAT I-beams from Kaag, but I can't go their on saturday I have to work.

The other stuff is ordered yesterday at vwspeedshop.co.uk.

Engle FK8
CB Straight cuts
CB lightweight lifters
Manton pushrods lightweight
Dual springs
Chromolly retainers
shadek 26mm
Gene Berg fullflow cover
Kennedy racing stage 1
Daikin super disc


A question btw, should I swap out the brazilian oil pick-up tube for an original german one??

Did you get the shuffle pins at the maincenter?

I am curious about what John Mayer thinks about that mod as I read not everyone thinks it is nescessary.

Michael

No I didn't get the shuffle pins. I believe that when everything is balanced correctly and torqued to the right spec it shouldn't be a problem on a 1915.


But why are you reacting on a non cal-look car?  ::)

It doesn't have to be a cal-looker to be liked by me ;)

Michael

Early Christmas :)

(http://www.cal-look.nl/gallery/albums/userpics/10013/IMAGE_036.jpg)


(http://www.cal-look.nl/gallery/albums/userpics/10013/IMAGE_038.jpg)

Kenndy Racing Stage 1 1700lbs
Daikin Super Disc
Engle FK-8
Shadek 26mm pump
Gene Berg Full-Flow cover
CB Straight cuts gears
CB 30mm Lightweight lifters
Manton lightweight pushrods

Hope to recieve my rods tomorrow.

good choice.
I think You should ubgrade to the german pick up tube. Paul has them new if You wont just ask him.
the brazilan aren't bad but the ending bit sucking oil is always on wrong engle. that doesn't metter if You're not running with oextra oil sump but if You are the extension will be cockeyed.

I have an original pick-up tube lying around from an old case, but I can't seem to get the old pick-up tube out. It isn't fixed anywhere else besides the nut at the pick up end is it?

Some rods cam in :)

http://www.cal-look.nl/gallery/albums/userpics/10013/IMAGE_039.jpg

Not fixed in other than a mild interference fit where the tube enters the case. If you are not reusing the old pickup (and I wouldn't be) then take a wide faced chisel and and give it a few whacks with a mallet where the tube meets the saucer part, that should free it from the case.

tom.

Thanks, I managed to get it out and put in the original one.

I have a question, all the parts I bought are balanced, should I balance them also all together?

yup, all together! that's the main key!

Hey nice progress going on here!
I even bought a new case after I splitted 3 cases. You don`t wanna build a exclusive house on an dubious
fundament  ;)

As said balance everything even together with the kennedy.I switched from VW clutchpalte to a kennedy out of the box now I have some vibrations at and rpm range that weren`t there before...

Go on,
Felix

Hi Felix,

But now you have Brazil on the side of the engine instead of germany  ;D :D

I'm having the machine work done in the next coming weeks, drill out the heads voor 94mm pistons and cut them for dual springs. And balance everything together. Hope that it makes a sweet running engine.

Still debating on the IDA's, going for new ones (very good price now with the low pound) or going for second hand italians....


Jesse/DVK

keep in mind the used items may not prove to be ready to use or in good state.
i know  ;)

even with the new Spain IDA's,sometimes you don't know what you're getting,cause they can come with bad floats :P

No no, on my case stands Mexico ;) But the best would be a new D one but not available even for good money...
The Mex and brasil cases need some smoothing inside the finish is way beyound compaired to an D case.Just lay them side by side and you see the areas which need to be smoothed

To the IDA`s:
I have bought spanish one`s and you really need to take them apart complete, two co-screw`s were bent and chisels inside the body and the overall quality is not that good.If I hadn`t bought them I would buy these:
http://cal-look.no/lounge/index.php/topic,7675.0.html
ITALIAN`S,40mm Vent. 3rd hole,rebuild, floats opend and polished nice deal...

Greetz!

Mexico, brazil, all the same  :D

That is nice deal, but i'm spending my money now on balancing etc. :).

Just a question, I would like to build the longblock now and than save for carbs etc. So it wil take like 2 months after the longblock has been build before it would start up for the first time.

Is this a problem for the greasing of parts and the stuff you put on the cam etc? Will it vaporize or something?

hoi Jesse allemaal heel leuk die gagets maar als je al niet weet wat je wel en niet kan doen dan word het een hele dure hobby
on the other hand if you need any advise or support ill be glad to help you out to make sure that you run that engine like you stole it with no problems at all .

groeten HENRI. ;)

Hi Henri,

Well you can help me by answering my question. :D

I think i'm well capable of building an engine. I just want to make this sure.

Ok Jesse dust sticks on any kind of lube, like a magnet on iron ,even if you wrap your engine in it stil wil be full of dust when you open it ,we use high pressure hot tanks to clean our engines and if we have to wait for any parts we store them dry ,even after that we inspect the parts and clean them out with a solvent or the hot tank
and about the grease its liquide so even after a small period of time it drips off !
my suggestion is to wait with the assembly till you have all the parts in hous an then fire it up !!!!!!!!!!!!!!!!!!!!

KIND REGARDS HENRI.

Jesse,you can do it man :)Thumbs up ;)

jesse, i'm gonna wait till i have all my parts and then get it done in a matter of days.
i've been wondering the same thing but it's not a good idea to assemble and let it sit for a long time...

Ok guys, I'm looking for carbs now. I can't really decide. Spanish IDA's (looks like DRD sells a good products they are checked and have a 3rd progression hole drilled) voor 1050 dollars or look for Italians? Are all the parts still available at normal prices? Or maybe I should go for another type of carb? IDF, DNCF? Car is street drivin on a regular basis.

Jesse,have you thought of 44 and 48 Idf's? :)I know they are not as cool as IDA's,but they should be easier to tune and better for street and everyday driving.

What If rain starts sipping into you IDA's ;D

No doubt,IDA's are much sexier :-*

Today I recieved two big boxes from the vwspeedshop :). Looks like I almost got all the parts now to start building. Sorry for the bad pics, the battery of the cam was empty so I used my phone.


(http://www.cal-look.nl/gallery/albums/userpics/10013/normal_IMAGE_071.jpg)

Cilinders/pistons, bearings, flywheel
(http://www.cal-look.nl/gallery/albums/userpics/10013/normal_IMAGE_073.jpg)

30hp fanshroud with doghouse
(http://www.cal-look.nl/gallery/albums/userpics/10013/normal_IMAGE_074.jpg)

good job jesse!

Look what the postman brought :):) So happy! Finally a set of IDA's!

(http://www.cal-look.nl/gallery/albums/userpics/10013/Engine_011.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Engine_010.jpg)

How should I check em out?

Some progress again.

Checking all the clearances etc. Got my CB equalizer pulley.

(http://www.cal-look.nl/gallery/albums/userpics/10013/Engine-014.jpg)

Porting my manifolds for my heads

(http://www.cal-look.nl/gallery/albums/userpics/10013/spruitstuk.jpg)

A crappy pic of my new dash layout. Monster tach and two VDO gauges.

(http://www.cal-look.nl/gallery/albums/userpics/10013/IMAGE_088.jpg)

I'm going to the Otto Bros next week to have everything balanced and some work on my heads so after that I can start building :)

A quick question. I want to run SS braided lines with AN fittings for fuel lines from regulator to the IDA's and oil lines. What size should I use? -6 or -8?

as far as I know most people run -6.

For both fuel and and oil? I'm thinking of a Mitsuba pump (max 4psi) up front under the tank. -> stock fuel line to the engine -> Holley regulator with 2 outlets and a gauge with -6 hoses to the IDA's. Should be fine I guess? And run -8 to the oil filter? -8 hose from Summit has an inside diameter of 0.438 inch which is 11 mm.

nope, oil is -8 and 12mm hose if i'm correct.

Would using -8 also for fuel be a problem?

Who can tell me where to take weight on Mahle 94mm A pistons to get the weight 5 grams down?

have you balanced the pistons?

Yep :). Everything is ready. Today I lubed the IDA's. Checked piston ring gaps. I'm just waiting for my parts to come back from balancing etc. Also ordered a 4qt Berg sump and Pauter pushrod tubes.

Yeah.....Almost party time ! :D 
We see the movies if your bug soon in youtube  ;D

Hope this mouse engine is still intresting for you guys  :)

Yesterday I went to the Otto Bros is Belgium to pick up my stuff. Everything is balanced and my heads are bored for 94mm and cut for dual springs.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02193.jpg)


I'm installing the valve springs at the moment. This sunday Diederick wil come over and we will start with the trial assembly of the engine. I will post some pics than.
(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02194.jpg)

Keep us updated  ;D
What rockers are you using? It looks that they are already rusting ???
Maybe you should dip them in WD 40 for a while...
Greetz!

Those are Bugpack rockers, lying around here made them a bit rusty but they are already cleaned up :). Today I put my crank with rods and camshaft with lifters in the case and put it together. Now I have a problem. When I turn the crank clockwise (looking from the pulley) is stops after a half turn. When I turn it counter clockwise there is no problem at all. Any ideas of you guys? The cam to lifter clearance is 2mm so thats ok.

is the Dist. Drive in the case? some guys put it in  at first and when rotating the motor one way it pushes the drive up and the brass gear binds  it could also be the crank and cam gear, your case could of had a -1 -2 or -3 gear before  turn the crank backwards and see if it spits the cam up out of the cam bearings 

putting the dist drive in there before the crank is generally the way to do it, right?
we'll have a look tomorrow jesse ;)

I took it apart and put it together and now it works fine. Donnow why :P  ;D

it was most likly the dist Drive I always check the play and the shimming before I put the crank in then I take it out I put it in after the shortblock is together I use a a little white grease on the shims and stick a push rod as a guide down the dist. hole and slide the shims down the pushrod then remove the push rod guide and drop in the Dist. Drive then stick in a cre dist so the drive dose not move up when you rotate the engine on the stand when building an HP motor I like to leave it out till last that way you dont get a false  tight spot felling by the drive not being down all the way plu if you force turn the motor you can screw up the brass grear

Some pics :)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Case1.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Case2.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Case3.jpg)

 8) looking awesome dude

oops double post lol

I need your expertise guys :).

I'm measuring my pushrod length. Full lift was 13.5mm so half lift is at 6.75mm.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02237.JPG)


Half lift

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02236.JPG)

Zero lift

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02238.JPG)

Full lift

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02239.JPG)

I think the pushrod lenght is ok. What do you guys think?

Hi Jesse I was just looking at the pictures of your engine and Noticed it looks like #1 Rod is upside Down The tab always faces up on the rod and the tanges for the rod bearings always face down when installing on the crank Please Check it before you go any futher on your motor if you have already checked the deck  and the rod is upside down you will have to recheck your deck  Hope  I caught it in time also check #2 Rod I could not see it good in the Picture  A lot of guys hang the rods on the crank like that if you have all the rods facing one side when installing them when you flip them over two will be upside down Good Luck Shubee ;D ;D

Good trained eye!
Yes it looks as if the mark is downwards on the rod.

About the rocker geometry:
Here is a perfect "how to" about rocker geometry on non orig. style rcockers:
http://www.pauter.com/RockerInst.htm

Nice progress go on and on!

Tabs up, Tangs down. I had to adjust this at the last moment because i did wrong also  :o  If you have rods without the tab's you can always recognize them on the tangs, they always must be down to scrape the oil. ;D

Thanks Gary, you have been a real help. What a stupid beginners mistake..  :-[

Felix, thanks I will look at that. I think they are all of the correct length now. I'm trying to get my shortblock, maybe longblock together today. Maybe I can make it to Bitbug :).

Hi Jesse,
hope that you make it to BITBUG. I am sure you will!

Then you can participate at the DFL 402 CAL LOOK Trophy  that will take place there ;D
More infos about DFL 402 in the following days!

Greetings!

LOL Jesse We All Learn from Are Mistakes I am just Glad I noticed it before you got it all together and in the car That's what the Cal Look Lounge is all About Helping each other Out any way we can.. Good Luck and have a Happy VW Day ;D ;D

Shortblock is together guys :). I just need some tools to get the longblock together.

  Cool Congrats ;D ;D ;D

just a general question also with regard to my own build;
shouldn't the process from shortblock to final engine take too long before the cam lube drips off??

 8)

(http://www.cal-look.nl/gallery/albums/userpics/10013/longblock.jpg)

COOL COOL! Are those orig. DDS tube`s ?  ;)
Go on...Will it be ready for Bitbug?
I hope You and your club mates attend DFL 402! Would be "über" cool!

http://cal-look.no/lounge/index.php/topic,9191.0.html

(http://cal-look.no/lounge/index.php?action=dlattach;topic=9191.0;attach=30555;image)

Had some bad luck with my thesis for school these last weeks. Haven't been to any meeting (Bitbug, Budel, EBI 3) which I wanted to go :(. Just have been busy with school and work. But last Sunday I did some work on the bug. Engine is in the car. Just need to do some small things and than it is ready for the first start up.

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02377.JPG)

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02376.JPG)

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02398.JPG)

(http://www.cal-look.nl/gallery/albums/userpics/10013/DSC02399.JPG)

Just a short movie of it running. No tuning yet :)

http://www.youtube.com/watch?v=s8pHuH1IfIo

rock on dude!! i'm real glad you pulled it off  ;D

Sweet dude! sounds Awesome!  8)

Bit faster than your old 1200 then?  :D

What breather did you use?

You got any Pics?

Cheers

peach, the breather is that ridiculous UK made tube above the shroud  ;) ;D

Hey very cool that it is running!
Sound`s a bit out of sync but already nice.

So some DVK members will go on the track at DDD, see you at the tree  ;)

Greetz,
Felix

Hi Felix,

Thanks! Yes I didn't synch or jet it yet. I'm sorry but the DVK won't be at DDD. We have a dragstrip here in Holland at the Kever Zomer Festijn. (www.keverzomerfestijn.nl) we want to promote the cal-look/dragracing in Holland so that where we are going.

@ Peach, diederick is right. It's from the vwspeedshop.

Finally sombody is going to try to promote dragracing here in holland ;D

Drachten has an official strip too only nobody wants to ride there

That's because you must be able to drive back in time when you go that far north. ;D

Michael

Long time I posted here. :P. Been busy with the enginebay because I wasn't happy with the way it looked. Painted the firewall and powdercoated all the engine tins. Look good IMO :)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Bovenaf.jpg)

(http://www.cal-look.nl/gallery/albums/userpics/10013/Motor.jpg)

Hi Jesse!  Looks very cool  8) Next week Ninove??

Thanks Paul! Yes I'm going to Ninove with the airmight cruise.

Long time no updates. Had some troubles with this car. Stock gearbox was destroyed. It has a built gearbox now with close ratio 3 & 4, SAW axles etc.

Also the complete front end has had an overhaul.. spindles etc and CSP brakes.

(http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs412.snc4/47486_1388925525280_1296347594_30879257_3322013_n.jpg)


Very small clip..
http://www.youtube.com/watch?v=ESVVD_GO_Bo

rock on dude! 8)

time to eat tarmac and burn some rubber at DDD! ;D

enjoy! :-*

enjoy the weekend .....
and can i take it for a little spin so i can use the gearbox at least once  ;)

Hey Jesse,

cool that it runs again and you solved the problems. See you at DDD!  ;D

Drove 800kms last weekend, made 6 runs @ DDD with no problems! Had a great weekend! Racing, watching, beer & burgers @ DFL (thanks guys!).

A cool pic shot from the weekend.

(http://www.cal-look.nl/gallery/albums/userpics/10003/260~0.JPG)

But I want to go faster! Looking for a set of new heads that suit the FK-8. Also changing the ignition to a CB/MSD and the exhaust to one from A1 (thinking of 1 3/4). Is that to big? Any tips for heads to look for?

1 5/8 will be big enough. for heads you can take a look at steve tims heads: http://www.thesamba.com/vw/classifieds/detail.php?id=185137
Kristof

 ;)

Got some more from Niels Airmighty!

Both of us, wayy cool... had to do that more often :P

More on airmighty!

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_7999.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8009.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8013.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8014.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8017.jpg)

Dragster look  :lol:  :lol:
(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8019.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8020.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8021.jpg)

(http://www.airmighty.com/index/Gallery/albums/das_drag_day_8_2010/IMG_8026.jpg)

It's winter again so time for some updates!

Ordered a A1 lowdown header and muffler yesterday. Will also rebuild the engine.. 78.4mm DPR.

Still looking for a good pulley, have had some troubles with the equalizer from CB. It welds itself to the crank.. I like the Jaycee pulley, anyone any experience with them?

Perfect ride dude!

What filter socks are you using? I´m looking for a set for my idas but can´t find any. :-\

Thanks!

Also the rear was lowered because it was to high  ??? Looked stupid at DDD :).

Filters are custom made by MotoAir. About 50 euros for 4.

http://www.motoair.nl/home/index.asp

Thanks! I´ll send them a mail... :)

I'm still debating on heads.. Choosing between CB wedgeports or Steve Tims Stage 2 (maybe plus)

that's going to be a nice engine  ;D

i,m thinking of Steavs heads but we will see and fk8 or a CB 2288

Just placed an order for a set of Steve Tims Stage 2 plus heads :).

lucky man i have to Waite to January to do that i,m thinking of going for the stage 1 heads.
what compres ion are you planing to run??

Chambers 53cc so with 1mm deckheight I will get 10:1 CR.


Just found out that a set of Mahle B pistons is no longer available.. Just USD 50.00 difference between a set of Wiseco pistons or a complete cilinder/piston set of Mahle. Do I need anything extra with the Wiseco pistons?

aircooled. fi  have aa and mahle

http://aircooled.fi/shop/index.php?categoryID=381

http://aircooled.fi/shop/index.php?categoryID=273

i think jesse means pistons only, no cylinders since he still has those...

no problem

http://aircooled.fi/shop/index.php?categoryID=274

http://aircooled.fi/shop/index.php?categoryID=382

send a mail to tompa and ask top service all my parts are from them so far

Thanks for the info.

I'm also looking for a new pulley. Anyone have any experience with the Jaycee Pulleys? Or should I go for a equalizer pulley.

Do I need anything extra with the Wiseco pistons?

Just a decent set of snaprings. (the piston pins are made in Taiwan, i'm having those checked on hardness).

How do you do that ,hit it with a hammer  ;D

gr henri

hey Jesse,
I will dismantle my engine soon and will install wisecos,
if you need my pistons let me know,
i dont need them anymore...

cheers, P

Normally you could use the following processes or methods: Rockwell, Brinell, Vickers, Micro, Mohs and Scleroscope (the Hammer method). Fortunately i can also have the pins and other parts checked on their metal and bi-metal (crap) substances within 5 seconds.

Regards,
Harry

Parts should be arriving soon.

Also ordered a Gene Berg Equalizer :).

Will me engine benefit from installing larger vents in the IDA's? What size should I use?

with stage 2 heads? 40mm is my guesstimate, but you're better off waiting for more profound advice  :D

Started on the bodywork.

Going to replace the rear valance and make it removable.

(http://cal-look.nl/wordpress/wp-content/uploads/2011/01/foto-300x225.jpg)

Bumper brackets are also a bit rusty so going to replace them. Also these are not the correct ones but for 1972 and later beetles

(http://cal-look.nl/wordpress/wp-content/uploads/2011/01/Bumpersteun-300x225.jpg)

Took the engine apart.

(http://cal-look.nl/wordpress/wp-content/uploads/2011/02/DSC00215-1024x768.jpg)

(http://cal-look.nl/wordpress/wp-content/uploads/2011/02/DSC00216-1024x768.jpg)

(http://cal-look.nl/wordpress/wp-content/uploads/2011/02/DSC00218-1024x768.jpg)

nice work!
but is that (premature) wear on the lifters?

nothing special on the lifters, are okay.

I will take some better pics. If they aren't ok I'm going for UDO tool steel lifters!  :o

update required?  ;)

Well waiting on parts now :). Brought my case to the machine shop for checking and shuffle pins. Furthermore I'm cleaning my inner wheel wells. Lots of Tectyl was put on them by the previous owner.

Cleaned all the parts I'm using from the 1915cc engine.

Received some new parts from Jo Clifford!

GB gland nut
Kennedy Stage 2
Daikin disc
Fast fab breather box

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00329~0.JPG)

Picked up a '64 convertible decklid yesterday. Hard to find as they are one year only. Cool thing that it's also java green :D

(http://www.cal-look.nl/Gallery/albums/userpics/10013/183535_1592018042466_1296347594_31258230_7778417_n.jpg)

And working on the body :) Next week off to the painter!

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00336.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00337.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00338.jpg)

loking good

nice!

Some work..

Damn it was a mess, lots of butchering from the past but underneath it revealed good condition original steel :).

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00349.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00351.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00355.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00360.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00359.jpg)

Nice work Jesse!..... :)

Thorsten Pieper tool steel lifters. 55 gram each. 

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00375.JPG)

Off to the painter

(http://www.cal-look.nl/Gallery/albums/userpics/10013/Spuiter.jpg)

painted?  ;D

Not yet! My painter is on holiday for two weeks :(. But I will get it back on 10 May. Ordered the last parts this week (pauter rockers, some JayCee and Berg items) and I will receive the A1 exhaust, DPR crank/flywheel and steve tims heads and the end of may so I have to hurry to get in finished in time for EBI!!

Painted?

Yes, it's being polished right now and I will pick it up tomorrow.  ;D

Sweeet!  ;D ;D

 ;)

Here we go :)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/Front.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/Rear.jpg)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/Engine.jpg)

 8) sweet dude  8)

nice! 8) seems like only one to two full days work to get it complete :)

Put on some fenders etc :).

(http://www.cal-look.nl/Gallery/albums/userpics/10013/WIP.jpg)

And new stacks

(http://www.cal-look.nl/Gallery/albums/userpics/10013/Kelk.jpg)

Nice!

Maybe you want to switch that yellow plastic "things" against HD supports made by VEWIB out of OEM castings.
http://www.ge-ma-classics-shop.de/index.php/cPath/8_90_302/category/hinterachse-kaefer-karmann-typ14.html

Very nice pieces and they aren`t higher like the yellow one`s which lift your engine & gearbox and could get you into shift problems. Lay both side to side and you see what I am talking about.

The HD spring plate bushings are even wonderfull and non comparable to the red plastic litter which even aren`t correct in measurement.

http://www.ge-ma-classics-shop.de/index.php/cPath/8_90_302/category/hinterachse-kaefer-karmann-typ14.html
http://www.vewib.de/cms/website.php?id=/en/brand.htm

Have fun.

A1! And Steve Tims welded heads :)
 
(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00596.JPG)

Nice!

My cars :)

Crankshaft etc will be balanced tonight so I can start building the engine this week and weekend. Deckheight came out to 1.25mm which is ok with 53cc heads. 9.8:1 CR

(http://img543.imageshack.us/img543/5632/dsc00636a.jpg)

Worked quitte some time on the engine this weekend. Hope to start her up next weekend!

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00661.JPG)

Pushrodlength
(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00663.JPG)

Back together

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00665.JPG)

Almost done
(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00667.JPG)

looking good....when it's running okay i have the next engine to build for you  ;D....
see you at Budel ?? or engine time this weekend ?

Engine time this weekend Hans! Just finished mounting my breather box, coil, wiring etc. Putting in the engine tomorrow night and than start up this Saturday.

Maybe Budel on sunday depends on the weather.

Building your engine is no problem! We will discuss it :D

Where's your pick-up tube ???

Removed it with trial assembly and to clean the case. Didn't forget it Zach ;)

So put in the engine and cranked for oil pressure. Everything ok. But than we found out that the magnaspark 2 coil was leaking! They are hard to come by in the Netherlands so thinking of replacing it with a MSD blaster 2 coil. Should be ok?

Anyone has a quick answer if the MSD blaster 2 or high vibration coil will work with the magnaspark 2 and magnaspark 2 wires? The coils have the same specs so I guess it should be ok.

too bad the coil is malfunctioning, one would expect more of a new product.
where will you get the MSD coil?
have you contacted CBPerformance yet? perhaps a quick phone call would help.

Just ordered a MSD High Vibration coil at a local Honda/Tupperware tuning shop :D

Fired her up! To bad she is leaking at the valve covers. Need to sort that out.

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00700.JPG)

looking gooood!
perhaps someone can chime in how on earth you got an oil leak at the valve covers??
the oil pressure was fine, right?

 8) 8) awesome dude, what exhaust have you got on that?

A1 lowdown ;)

Now that looks perfect!
What v.covers are you using? I learned that it`s always a good idea to "glue" in the sealing in the aftermarked v.cover with dirko HT or other simular products.
Have fun!

Stock but they are do not have enough room.. Have to find a solution quick before EBI!!

good luck man some body here can help  you

Beautifull engine man :)

Thanks! Just ordered a pair of SCAT valve covers which should work perfectly! So EBI here I come!

Small vid!

http://www.youtube.com/watch?v=NLbnvS1_GrY

Sweet dude looks the dogs!

Have you got any tips for first time start up? like cam break in etc?

buddy, you busy at work or something? i sent word...
are YOU ready and set for tomorrow?  ;)

So is this all done now then dude?

Yeah, tell us how it drives Jesse  ???

It ate a Dodge SRT-10 for breakfast.  :-\

Nice  :D

gr
Wout

any new  videos?
i,m waiting  parts to finish my engine no i have a 1200  :'(

Good lad!! :-)

I bet that tasted sweet!!  ;D

Whatch out for indigestion later on hehehe  :D

J

Soon more vids Freddy, going to get myself a GoPro HD :).

Took of the bumpers and put on some cheap T bars. If I like the look (not sure yet) I will get some nice hex bars.

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00824.JPG)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC00823.JPG)

What do you guys think.

Looking good!

jeezz that took a long time  ;) Lookin' good!

oldstyle plate will do much too!  ;D

So a small update. Wasn't happy with the engine. Had a bit low oil pressure and wanted some more CR. So I took it out to check everything. Turned out my pick up tube and oil cooler were loose!  :o. Furthermore the heads were reduced from 53 to 48cc. CR will be 10.7:1

It didn't have a plug in the oilgalley, now it does and I welded the pick-up tube.

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01207.JPG)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01184.JPG)

Longblock together again.
(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01269.JPG)

Bought a Cagero oil cooler.

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01246.JPG)

Jesse, how did the Mahle cylinders / Wiseco pistons look after teardown ?

Harry

Harry, I don't have Wiseco pistons but I could get my hands on a set of Mahle B's. They looked very nice but had only run about 300 km :P

And the engine is back in the car :)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01296.JPG)

Finished

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01360.JPG)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01364.JPG)

(http://www.cal-look.nl/Gallery/albums/userpics/10013/DSC01365.JPG)

No T-bars ?

looks good and well on time for  2012         have fun....

Thanks Hans!

@ Harry, no this is my street trim. For racing T bars :D

Last Saturday I went to the dyno to have the engine jetted. Very happy with the result, 187.9HP and 231NM of torque!

http://www.youtube.com/watch?v=2yUrsgSlX4o

Furthermore I went to the Ninove meeting. Car held up perfect and it runs so smooth!

(http://www.cal-look.nl/Gallery/albums/userpics/10003/normal_099_modified.jpg)

Congrats with a very good result. Around 200hp without the fan belt  :)

Do you have any idea why the dyno guy increased the roll resistance and planted the pedal to metal a couple of times in 4th gear?

-BB-

Nice  :)

Which rpm did you get that result... I am just curious because my engine is same size (2165) and I should also go dyno in may...

-Petri-

Thanks!

@ BB , I thought to see how it runs under load, to see A/F and response to full throttle. Hick up etc. Changed to 110 idle jet holder which improved it alot!

@ Pep Max hp @ 6000rpm and torque at 5400 rpm. But I already have over 200NM at 3250 rpm.

Jesse,

Nice build, car looks great. Always been fond on that color. Not to doubt you but that must be a pretty stout 2175cc.  187hp at the wheels equals 224hp at the flywheel. I thought my 2332cc that made 210hp at the flywheel was stout. ???

Verry nice results Jesse!,Good job.
And a clean nice car .
Drive safe dude

gr Henri

Thanks Henri! Looking forward to this season!

@ Dano, sorry the 187 is flywheel hp. But 210 out of your 2332 also sound nice!!

Nice build, what is the cameshaft?
Thanks

Jesse, that makes sense. I was thinking WOW that motor is pissed ;D Nice build Jesse and enjoy pounding the V8 cars...
   

webcam 86-c