Operation: 2276 . . . Deadline: October 3, 2009

[Kenney]

Parts are really beginning to poor in for this thing now. It will be going into my cheap-o-resto-cal-look-POS 1967 Beetle.

Here's a breakdown and snapshot of what I do currently have on-hand:

AS41 Case  (clearanced, full-flow, cut for 94mm Pistons, cut for sand seal)
DRD L6 Heads (42x37.5 valves, Oval ports, Port-matched Big Beef manifolds)
DRD 82mm Crank  (balanced)
DRD 5.4 (more specifically 5.394mm) H-Beam Connecting Rods
Engle FK-44 Cam (clearanced)
Scat Lifters (SLR-treated, non- lose-a-lobes)
Scat 1.4:1 Ratio Rockers and Lash Caps
Clevite Rod Bearings
Mahle Crank and Cam Bearings
Schadek 26mm Oil Pump and Cast Oil Pump Cover
CBPerformance 1.5 Qt Sump

Other miscellaneous/top-end parts include:

Full Mallory Ignition System (Dual Point Distributor, CDI Box, and coil)
Weber 48IDF Carburetors
36HP Doghouse Fan Shroud
External Oil Filter and Oil Cooler w/thermostat
1 5/8" A1 Sidewinder Header and Muffler
and more



Stay tuned for more. I intend to take as many pictures as possible during the build out. I will also stop and shoot videos of alot of areas as well. That, of course, including break-in, tire-roasting, etc.

Kenney

[Kenney]

Well, I've obviously made the terrible decision to order my parts when I did, as there's a TON of parts on back order, including (but not surprising) the A1 Sidewinder, Cylinder Heads, and even my carbs.

Either way, i'm going to start with cleaning out the case and getting the head studs in, fitting the bearings, assembling the crank, and a few misc things here and there. I plan to get started on this tonight.

Feel free to chime in with any questions, thoughts, opinions, and tips.

Kenney

[admin]

Rock on brother! 

I think too many people think because it's the VW industry that people will wait for parts.  Sorry, I'm an American and I don't wait for fast food, or the microwave to finish cooking!

I'd call some retail shops or check their websites and see what might be sitting on shelves at stores.   You might get some good stuff there and not have to wait forever to get your parts.

Good luck with it and I can't wait to view this developing thread!

Scott Faivre

[Kenney]

Thanks Scott.

Luckily, I've got an incredibly slow day at work today (i.e. nothing to do) but call around and find me a set of heads in stock, a cam that's ready to ship, and some carbs.

If it wasn't 300000* in my garage yesterday after work, I'd have gotten something finished. Going to pick up a small CRAC A/C unit I found on craigslist after work. Should solve the heat issue 

Kenney

[Kenney]

I'm REALLY glad I set such an optimistic date for finishing the engine.

With my car's limited range of a 1 mile radius, nobody within that area carries, or plans to carry green plastigage, permatex aviation, curil-t, yamabond, or anything else I need to make any sort of progress.

Go figure.

Kenney

[admin]

Do you know anyone with a bore guage?  I'd highly recommend that over the plastiguage stuff.  In a V8, that stuff will work well, but in our VWs it's hard to use.  With a piston in a v8 bore, the rod is secured.  With us, we'd have to install head studs, stick a cylinder on, and hope that it doesn't move around or fall off while we try to work with the internals.  Jason Vance bailed me out when I was fighting with plastiguage on my engine.

We measured the journals of the crank and the bores with my bearings installed in the rods and found out my clearances.  See if any of your buddies has a bore guage.  That plastigauge was just a royal pain in the butt!

Scott Faivre

[Kenney]

Sounds like a winner. I figured I'm stuck ordering everything through the internet anyways, so i guess i'll add that to my list.

I've used plastigage in the past and found a cool, cheap trick to using it without any fuss. Heck, you can even use it all by yourself.

We built a "jig" that held the crank (my GNX motor, at the time) by the end journals through 2x 4x4s lined with 1/8" strips of teflon to protect the journals. We built a frame around that and made the height adjustable (hard to explain). The bottom piece was a 2x4 that was planed on both sides. We then cut little semi-circular divots in the 2x4 for the small end of the rod to rest. Place the small end of the rod in the divot, lower the crank down so the rod crank is resting on the rod place the cap on and start torquing it down. Sure wish the I had the tools to do that again.

I'll see what I can find online for a reasonable price. I sold the one I had bought before Christmas, and never even used it.

Kenney

[Kenney]

Worked until about 3am last night. Not bad if I wasn't salary!

Anywho, I screwed around in the garage cleaning off my workbench to get ready to start building this thing. So, for now, here's a ton of pics. A TON!

SCAT 1.4:1 rockers, allen adjusters w/ lash caps


Balanced H-Beam connecting rods


2.3L is RIGHT!


Fly cut Pistons for balancing? I'm used to seeing them drilled on the bottom side of the crown


Another shot of the fly cut


Case


Full Flow


Full Flow


Extended Pickup Tube


Clearance work


More CNCd clearance work


The next pictures I post will hopefully display some progress and the above parts will start being put together

Kenney

[admin]

Dude those are some exciting pics!  The work looks good!  Now what you want to do is spend some time detailing the inside of that case.  You want to knock off all the hard edges from the CNC cuttings.  Smooth that out and you'll be sure that there is no burrs or sharp edges that can be the start of micro fishers in the metal.  Some guys will say to polish the entire inside of the case, but I think that is over kill.  I just used a tiny die grinder and a wire wheel.

Can't wait to see this progress!

Scott Faivre

[Kenney]

I moved to the other side of town and seem to have forgotten to bring both my car and my engine with me.

Actually, I haven't forgotten a darn thing. Kinda sucks that I used to have nothing but time and no money, and now I'm in the exact opposite position.

I'm hauling the car up to the house, along with my tool box (sigh) and the car and really getting crackin' on this thing.

It doesn't look like the car is going to be finished in time for the Las Vegas BUGORAMA this year, but the engine and trans sure will be. That, the brakes, beam and a few other goodies. Maybe i'll have this thing ready to go for the start of next season and get it ready for some track time down in So Cal to get me prepared for the track here in Vegas.

Hope in one hand and you know what in the other and see which one weighs more, right? More to follow in the next couple of weeks. My apologies for the lack of updates. 

Kenney

[admin]

What???  YOUR FIRED!!!!!!! 

Just kiddin'...   We've all been there.  You'll get it done.  Just keep pluggin' away at it.  Even one small project per week will lead to major progress in only a few short months.

Scott Faivre

[gblakeney]

Wow this brings back some memories! ! ! !

Nice work!

I have Curil T and Curil K2 if you still need it.

I built my 2nd 2276 and took it down to Geoff Hart's place in Lake Havasu for break in / dyno. Low compression, Tims Stage II heads, 1.25 rockers, 44's, WebCam 218, Mallory SVDA and 6AL, 1 5/8" A-1, DTM, CB H beams, Mahle 94s / rods / cam brgs.

Had a problem with the Mallory distributor on his Dyno, so ran an old 009 he had laying around. Got over 150Hp at one point. After peak tuning across the RPM range, HP came down to 146 at 5,500 and 160 ft/lbs at 3500.

Max torque at cruising RPM - I am happy!

Keep up the good work!

[Kenney]

Thanks man!

I guess I should edit the title for Oct 3rd of NEXT year. 

I've changed things up a little bit, and will most likely have a short drive/drag engine. I'm looking at a much more radical cam (FK-89 probably), cnc wedge ports, much higher compression, mega squirt EFI on Extrudabody throttle bodies of the 50mm variety, and a cheap exhaust system.

Maybe i'll get around to building and finishing this thing up when I have a proper garage to work on it in. Well, either that, or i'll haul it into my bedroom and build it there. Alot more space available. Sadly, because of the current situation i'm in, i'm really beginning to lose interest in all of this, but i'm trying.

So how long has the engine been in your SC so far? How many miles? Any issues?

Kenney

[Kenney]

Okay, so here's a stupid, quick little update. Not exactly progress related, but close. It'll help with the progress.

I'm "inheriting" about half a dozen 2-post server racks. I'll be chopping these things down to make an awesome workbench in which to assemble my engine.

I'm going to write up an article for part of this, as i'm integrating an engine stand, crank assembly station, and sometime down the road, a break-in station. That should be pretty cool! I'm working on a CAD drawing in my spare time (what little I have) that I can toss up so others can put together a kick-ass "engine assembly and break-in station."

Looks like i'm a little more into the car's tear-down than working on the engine at this point. Just trying to take it one step at a time. Most recent update on the car is here:

http://www.german-pride.com/Joomla/index.php?option=com_smf&Itemid=63&topic=345.msg2229#msg2229

Kenney

*EDIT* Atrocious Spelling