Carb problems
Anyway to test this, I borrowed a pair of 36 Dellortos from a friend, bolted them on and the engine runs so much better. I didn't have to fiddle with them at all. So the Webers will get put on the shelf, and I will source a good pair of Dellortos.
Engine support
Here are some pictures of the engine support bar that was made up (thanks again DrDub), and then powder coated (thanks Jeff). As you can see it goes up above the j-tubes and is solid mounted on the bumper mounts (i don't plan to run bumpers, if you did you could weld the bar supports onto the bumper irons). The bar mounts to the engine with the stock rubber mounts.
She lives!
Exhaust
Engine installed
I used my standard procedure for putting an engine in a beetle: Use a massive jack under the rear section of the floorpan, and jack it right up. Place the engine under the car, using a smaller jack. Rest the engine on blocks of wood (so the smaller jack can remain under it). Lower the car down onto the engine (careful!), then use the smaller jack to fine tune the engine height to slide it on to the gearbox. I have done it enough times with not enough jacks or not big enough ones, to know that a very large jack for jacking the entire car up makes life much easier. Once I had realised i needed to tip the engine up slightly to clear the fan ring, and that I needed to cut a small section out of the valence, it was much easier.
Good head
I have fitted my electric fuel pump to the bug, which was a bit fiddley, as space is very tight down there.
I have now got the pistons and barrels on, and the heads on. I have also put in the followers and pushrods on one side. Now left to do is finish off the carb linkage, which is causing a bit of a headache, and install the cooling system. I have decided not to use the deep sump for now, there is no point when I am running the engine in, and will just get in the way when I am putting the engine in the car. I also have a problem with my exhaust. The BAS header doesn't get anywhere near the shortened J-tubes without fowling the pulley. It could be that the j-tubes were intended for another style of header. Either way I am going to have to think again about the exhaust.. :(
Bottom end together
I still don't have my heads back from Microgiant, they have had to go abroad to get the inlet valves as they couldn't get them in that size in the UK. I sent them a set of 1700cc rocker assemblies which have allowed him to fit Ford Courier swivel foot adjusters which, according to Microgiant are better lubricated than the Porsche 911 type. Looking forward to getting them back, as its holding me up now. When they are back I will cc them and work out my compression ratio.
Fan ring
Goodies in the post
Straight-cut timing gears
I have decided not to use my windage tray, but will use a deep sump instead. I have heard reports of the windage tray causing problems with the oil backing up on top of the tray and not returning to the sump quickly enough. To fix this you have to cut the tray up a little. I managed to pick up a deep sump at the Volksworld show back at the end of march. That will allow me to run with a lower oil level (but still more oil than stock), which should discourage the oil to slop into the pistons and up into the heads. Eventually I would like to run a dry sump system.
Enthusiasm :(
Something that I forgot to mention was that a while ago I decided to machine down the fan ring myself. Well 'machine' is too strong a word, I just got the grinder out with a soft pad on it! I took the ridge out that runs all the way around it, allowing me to use the wide strap I have. I also flatted off the area at the base of the ring so it sits snugly on the breather tower cover plate.
Fan mounting options
Pretty fan
Microgiant
I have sent my heads off to a company called Microgiant to have a bit of work done on them. I know I need new valves, but I also wanted them checked over and ready to bolt straight on when I get them back.
I have also sourced a fan strap so I have started playing around with the fan positioning. I have decided that I will use some thin galvanised metal that I have to cover the breather tower under the fan, probably glued on. I will then put a rubber sheet on that which the fan can sit on. I will also support the fan from the middle, down to the engine case, just to keep things rigid.
Oil pump
Decisions..
Fan Strap
Case issues
Dubfreeze
Parts
I have started collecting bits and pieces for my engine. So far I have:
- Porsche fan assembly
- Fan shroud allowing for cooler in stock position
- Engine case, machined to seat the fan on the breather tower
- 2 litre crank and rods
- 1800 cylinder heads
- 94mm Pistons and barrels
- Weber 44IDF carbs and manifolds
- Shortened heater manifolds
- BAS exhaust header
- 050 and 009 dizzys
Most of these items were brought as a job-lot from a friend of mine. I picked the carbs up at Vanfest last year, for £200!