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Author Topic: The eternal rebuild  (Read 32206 times)
Peter Shattock
Sr. Member
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Posts: 302


« Reply #150 on: August 09, 2018, 05:52:07 AM »

Iíve had a bit of time on and off to put some street miles on the car this summer and the good weather has been great for the hot temp testing.

Iíve got to the point now where Iím happy I know where the car is with hot running and with the deck lid open it is manageable even when the outside air temp is in and around the 30ís which does not normally last for long here. It is a bit marginal at times and I do need to slow down every now and then, but itís manageable.

What has not been manageable though is the lack of charging but two regulators and a replacement alternator later it looks like I have a working system now. I had wondered with all the electrical power hungry gear I have in the car now I was just short of power which would have been a real pain but thankfully that was not the case and it all looks to be good to go.

With the new alternator fitted just in time for Bugjam I had a 1 hour test drive one evening in the week before the event to check it was all OK. Thankfully it was all good as I really wanted to drive the car to the track for the first time in quite a while.

So I was all set, a bit last minute, but whatís new. I had the day off on Friday so once Iíd dropped the kids off to school I packed up the car with all the gear and set off. SantaPod is about 100 miles from home and I had not driven that far in one go in any of my previous drives in the car, but I was confident all was well. Other than the traffic the drive to the track was fine and the car behaved really well, with good temps and pressures so I just drove non stop to get there as the track was due to open at 12 which was about when I arrived. As it turns out I didnít get to run on Friday as I wanted to change the oil check the valves and have a look through the car and check the data log and have a look at an oil leak that has sprouted. As it happens by the time Iíd unpacked and done this little lot it started to rain so the track closed early and that was that, but I was all set for the morning.

In the morning I got signed on and got the car warmed up and down to the start line. The first pass is always a bit of a moment (and generally a balls up) and it was no exception this time! I decided to skip the burnout and just drive it, which I sort of managed, but for stalling when trying to stage then I nearly rolled through, but just caught it in deep stage. It spun the tires hard of the line so a bit of a peddle to get going then I managed to barge into the Rev limiter on most of the shifts and was on the Rev limiter at the end of the track. The latter was a known issue as I was limiting at 9500 rather than 10500 as before. The main thing was though that Iíd got the first run under my belt.

Just being able to drive straight back to the pits with the engine being cooled on the way is a joy.
Back in the pits it was clear Iíd not resolved the oil leak though and the tinware was not such a joy when trying to find the oil leak given the fan had given the oil a rollercoaster ride around the engine bay.

The nice thing was that the push rod tubes were bone dry which was a major step forward as over the years I have spent hours trying to get them to seal properly, but with the short stroke and the increased pushrod angle I had failed miserably till now. I did end up having to make pushrod tubes and Johannes cut the heads at the correct angle which made all the difference. So the other oil leak is currently ruining joy of dry pushrod tubes. At least the back of the car is not going to rust away any time soon!

As it turns out my 12 year old son noticed a loose nut on the generator stand and it turns out they were all loose so I nipped them up and ran again but there was still oil. I decided this might be residual oil from the previous leak so mopped it up for one last run on Sat but there was still oil.

Sat night I set about taking it apart and having a proper clean up and putting new gaskets and glue on the generator stand. There was a fair bit of oil around on the inside of the tinware so I was hopeful it was good to go.

In the morning first run guess what more oil! Looked like it might be the 1&2 rocker cover this time so after the mop up it was a new gasket bend the bale to tighten it (thanks Dave) and it felt good and snapped on with some purpose. But of course the next run there was still oil. By this time we were into eliminations so there was next to no time to do anything but mop oil and go again. Typically its the only event Iíve ever gone rounds.
Fortunately the whole oil escapade was not lots of oil and any which did drip got caught in the tray so no dramas for the track but still very annoying and on top of the to do list now the car is home.

So eventually my luck ran out when I came up against Udo, but that was in the final by then. I did have a glimmer of hope when he missed 3rd gear and was catching him briefly but he found 3rd 2nd time around and had enough in the bag already to cover me off with some ease, but I was more than happy with the weekends work and just looking forward to getting the car home sorting the oil leak and getting the clutch sorted.

During the whole oil slick debacle what also came to light was that what I had hoped was a good clutch solution proved not to be. So in the short term at least IĎm going back to the steel pressure plate and a sintered iron disc for the next outing. I had gone back to the aluminium shoe and a new centre disc I had high hopes for but itís not worked out as I had hoped there is another disc option for me to try but I think that will need a bit more time to organise than I have before the next race.

Iím in California at the moment so hope to call in at Mcloed and sort out a couple of 180mm sintered iron discs as I know that is enough clutch and I have a steel pressure plate balanced and ready to go so is a quick fix.

The clutch was fine for the first few runs but the 5th run it was fine in the burn out (a short no line lock 3rd gear effort), but off the line it slipped. This actually resulted in the best 60ft of the weekend and pointed towards slipping the clutch a bit to keep the motor up in the rpm. Sadly the run after slipped more so I needed to manage it from then which meant no burnout to save the clutch for the start which was better but a compromise. Basically it got me through the rest of the weekend and the drive home, but itís certainly not the long term solution I was hoping for.

To complete the hatrick of drama the serial port on my laptop was not playing ball or at least it was not for the whole weekend. This meant I was struggling with any data logging, but it was a bit academic as the clutch that I was looking to monitor was clearly slipping without me trying to slip it.

Fortunately the Outlaw pit came to the rescue (thanks Darren) with a spare laptop so I could at least nudge up the Rev limiter so I was not stat on it going through the line each run. 200 extra rpm gave me 3mph (116-119mph) which was just about enough.

So the actual runs other than the 1st and last were all 11.2* actually between 11.24 and 11.26 with a best mph of 119. This was a big improvement on my proper street car pb (street tyres, fan belt and muffler) but mainly because Iíd not run the car like this in ages. Regardless itís the new marker to work from and hopefully I can now nibble away at this next time out with with a clutch and laptop.

Other than the general social and actually getting the car to the track for the first time in a long while was the drive home was really good. Whilst I was lording it up getting my trophy for 1st looser and packing Dave was moping oil and glue in another rocker cover gasket to the head and cover in a hope we would not leave an oil slick all the way home (thanks Dave). I decided to leave the oil try on just to see what difference it made to the temps and they did go up a bit perhaps about 5-10 degrees but sort of manageable in the traffic on the way home as it was all fairly slow moving for the first hour or so. Iíd been watching the temps and pressures the whole time as there was not much else to do and all was steady at about 100 degrees and good oil pressure on a really hot evening for us in the UK. So I was a bit shocked when I looked over at the temp guage to see it at 170+degrees! Fortunately it was obviously an electrical fault as Iíd only checked the guage moments before so there was no way it was a real temp reading. I pulled over and it turns out the sender wire had shorted out on the oil tray. So we took the tray off and problem solved and a minor job to add to the list to modify the tray slightly so it does not happen again. The rest of the ride home was plain sailing and the car behaved perfectly.

As ever it was great to drive the car to the track and generally having it as a turn key car again is the only way for me.

So Iíve a few jobs to do when I get back from the family holiday, but hopefully all doable in time to have another go in early October and get some decent street miles in before that.

Thatís about it for now, but Iíll try and post up video or 2 but a photo will have to do for now.

Peter

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The fastest blue beetle in the village
bean
Newbie
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Posts: 31


« Reply #151 on: August 09, 2018, 09:00:07 AM »

read through this thread after seeing the motor pics in a racing mag - major congrats on all the work and design thoughts that have gone into the car and i'll bet you're stoked at it now being streetable
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Peter Shattock
Sr. Member
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Posts: 302


« Reply #152 on: August 10, 2018, 02:17:30 AM »

Bean, the street car ting for me is the most important bit, but Iíve had a lot of fun along the way with the car and met a lot of good people too.
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The fastest blue beetle in the village
Peter Shattock
Sr. Member
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Posts: 302


« Reply #153 on: August 10, 2018, 02:29:42 AM »

I can fully sympathize with not wanting to take the car off the road - mine ran out of mot and insurance in early July so I took it off the road for a couple of months while I have holidays and housework and I'm really missing it! I'll have it back on the road when I start my new school in September tho!

Couple of questions about the data you're getting - what sort of sensors are you using for oil temp and pressure, and where do you have them located? I've still got my old VDO gauges for oil temp, oil pressure and cylinder head temp in a box somewhere, but haven't got around to fitting them yet. Just wondering what you do before I fit mine over the six weeks.

Neil, sorry I missed your post. Get the car back on the road as soon as you can is all I would suggest!

The senders are just regular off the shelf items from CB for the ECU and the Autometer gauges just use the ones they came with. The oil pressure comes off the old std oil cooler location oil temp on the galaxy where it exits so itís done the work and is off the the filter, cooler and tank.

Peter
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The fastest blue beetle in the village
Jim Ratto
Hero Member
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Posts: 7075



« Reply #154 on: August 10, 2018, 16:15:24 PM »

Hi Peter, this topic has become one of my all time favorites on the Lounge. Good luck with the oil leak issue. I fought one for weeks with my last engine assembly and it was a real bonehead move on my part. The new cylinder heads I am running have a reinforcement which interferes with # 2 and # 3 intake pushrod tube @ head end, IF you run the Type 1 seal. Once I swapped the seal to 411 style, no more leaks.

Have a good stay here in California.

Jim
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All animals are equal, but some animals are more equal than others.
(George Orwell)
Peter Shattock
Sr. Member
****
Posts: 302


« Reply #155 on: August 11, 2018, 03:04:57 AM »

Hi Jim,

Glad you like the car and my ramblings. Fortunately the oil leak is not a pushrod tube issue. Iím sure Iíll find it when I get back as I can take it for a short ride with no tinware on it if necessary then it should be more obvious with out it hiding under the tinware and the fan throwing it all over the place!



Given we are in the home of the Callook VW I was hoping to show the kids some nice VWís in their natural habitat, but to date the only AC VW we have seen is a bit of a clapped out super beetle, which was not quite what I had in mind. Having said that we have not made it anywhere near LA as yet. We are on a bit of a whistle stop tour from Vegas, Death Valley, Mammoth, Lake Tahoe, San Fran then down the coast to LA. We are not due in LA till a week on Saturday and we fly out on Thursday afternoon. This means we miss Irwindale so I was wondering if there are any other possible VW gatherings  or general car shows where we might see some nice VWís?

Peter
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The fastest blue beetle in the village
pupjoint
Hero Member
*****
Posts: 681


« Reply #156 on: August 11, 2018, 06:56:16 AM »

awesome updates Peter. I dint realise we can run EFI with generator. always thought the other way round.

What engine oil have you been running on this beast if you don't mind sharing.

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Peter Shattock
Sr. Member
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Posts: 302


« Reply #157 on: August 11, 2018, 15:32:25 PM »

Itís actually a generator look a like with an alternator inside hence the aluminium casing.

Oil is nothing particularly special Millers 10-50 I do like to change it regularly though, more than I need to I suspect but itís good peace of mind.

As I keep saying itís just good to be able to use it again as itís been a while, and prove there are no problems with using it on the street. The efi the short gears and light car make it ridiculously drivable.

Peter
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The fastest blue beetle in the village
andy198712
Hero Member
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Posts: 943



« Reply #158 on: August 11, 2018, 17:57:22 PM »

I used to run my mega squirt with a generator and it was okay before I went Porsche cooling if that helps?.... whatís ment to be the issue?
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broen messiaen
Full Member
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Posts: 124


« Reply #159 on: August 12, 2018, 09:17:56 AM »

Hello Peter,
Saw your car at bugjam and it's really impresive.

Are you using any headtemp sensor or are you only using the oil temp sensor?

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Peter Shattock
Sr. Member
****
Posts: 302


« Reply #160 on: August 13, 2018, 05:40:07 AM »

Hi Broen,

I donít run head temp sensors, but have contemplated them. Iíve got so much spaghetti in the back of the car now a few more would not make a lot of difference! That said itís not height on the list of priorities.

Glad you enjoyed Bugjam itís was a fun weekend for all of us racing there too, trying to keep the ACVW numbers up!

Peter
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The fastest blue beetle in the village
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