1385 supercharged project

[samotorsport]

So the Karmann engine is done , the Corona is still there , lets start something new.
Base is a 1200 cc with 90 mm opening , top notch condition ( coming from a fire brigade pump with very few hours and good service )
1300 dp original heads , AA big bore kit for 1385 cc , Amr 500 charger , Weber Dcoe carb ( only to be used as throttle body)
1600i intake manifolds with injectors.
Free programable ECU .

My question about the heads , i have to re work them completely .
My plan
Media blasting
Grinding out the cracks from the plug hole to the valves ( no cracks between the valves )
Welding up all the cracked stuff with WIG/TIG
And then ? First new seats and after this the guides ?
I wanna have the guides to guide the cutter to set the seat-holes .
The guides don t come loose that quick when reheating them to put in the seats i guess . 
After putting in the guides in , is a 8mm H7 honing good enough ? Or does it need to be more precise ?

[Garrick Clark]

Seats out.
Do the welding
New seats
Old guides out
Do the porting to blend in the new seats
New guides back in

[brewsy]

So the Karmann engine is done , the Corona is still there , lets start something new.
Base is a 1200 cc with 90 mm opening , top notch condition ( coming from a fire brigade pump with very few hours and good service )
1300 dp original heads , AA big bore kit for 1385 cc , Amr 500 charger , Weber Dcoe carb ( only to be used as throttle body)
1600i intake manifolds with injectors.
Free programable ECU .

Same same but different is Wally's awesome thread..
https://shoptalkforums.com/viewtopic.php?f=3&t=138482

Im on a similar quest but intend to start with a 69mm crank and keep 1285 (or around 77ish mm).
Instead of welding up a cracked pair of 1300DP's you might want to try and source a solid pair? Got mine from the engine rebuild place in Catford, London.
As my pair are solid my plan is/was to actually weld the spakplug hole up and then redrill for a smaller plug (diameter) so that there is then more meat  between seat<>plug although to be fair the cracking might be due to the fact that lots of people think/thought that 1300DPs ran lean and/or overheated regularly?

Looking forward to your build!

[samotorsport]

In the end i may need to find a solid pair of heads , but i got those in my shelf , and a WIG Alu Welder at home , same as a milling machine , therefore i wanna try to fix them myself . All big builders had to do their first set once , so why not giving it a try . If i fail I still can throw them away . But at least i tried
I am always up for new challenges . So here we go .
I gonna keep it posted here , even if i fail .
My plan includes to weld up the holes too so i can put in the smaller plugs .
I am not in a rush  and i hope that the cracked up heads will be more solid after welding them up then a set of not yet cracked heads waiting to start cracking .
 


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[samotorsport]

So give me your opinion
The crank is still the old style with a normal not elongated hole for the conrod oil supply



So either i notch them to the same dimensions as later cranks , or i put the bearing halfs onto the lathe machine , putting in a little groove on the inside to give the two center rod bearings a constant flow of fresh oil .
Max rpm is planned at 5000 to 5500 rpm .
Oil pump i think i go with a 26 mm

 


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[samotorsport]

The conrods are brought to equal weight , started with 1,3 gr of a difference , now all within 0.15 grams




The case is cleaned and checked , all ok , still gonna set the fullflow connection to it




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