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Current Page: 8 of 9
Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: May 22, 2018 06:50PM

Began to take apart a few starters to build a good one.

Turned down armature:



Cut down the mica:



Test on the growler:



So far so good, have to order a few parts... new bushings, brushes, leather washer...

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: May 22, 2018 06:57PM

Aren't lathes great!!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: The "mutt" grinning smiley
Posted by: Unsafe140 ()
Date: May 22, 2018 08:50PM

Man this ride is so close. Nice work!

Joel
Cave Creek, AZ
1965 Corsa 140 tele

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: May 23, 2018 05:38PM

Unsafe140 Wrote:
-------------------------------------------------------
> Man this ride is so close. Nice work!


I think I am going to stick a plain jane 110 in it if the compression check looks good. I would like to drive this for some of the summer and work out any kinks.

The take my time building the motor, I really want.

Degreased and got rid of a mouse nest.



I picked this engine up from Tom Z many years ago. He said it ran but that is all that he could say about it. Hopefully it's a decent runner.



I will be putting all new gaskets and orings in it and make it look nice.

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY



Edited 1 time(s). Last edit at 05/23/2018 05:39PM by toms73novass.

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Re: The "mutt" grinning smiley
Posted by: maxrevs58 ()
Date: May 23, 2018 09:58PM

Wow, beautiful job on everything!

Tim, Wright City, Mo.

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 06, 2018 05:40PM

Well got the engine stripped down to put in new gaskets so it doesn't leak hopefully.

Not sure when this engine was run last but there was a bunch of goo that had settled on the horizontal surfaces. Much of it was gray lead from the gas.

Really the only part that I didn't clean was the block/Crank/Cam area.

I think at some point the valves were misadjusted on the one side because all of the cylinders were low on compression. I pressurized the cylinders to do a leak down and all on one side were good, the other were leaking through the valves.

I backed off the rockers a bit and while under pressure gave them a wack with a dead blow and carbon came out of the intake and exhaust. I did this till the valves seal up. Now no leaking out of the valves and the compression test puts them all with nice compression.

This engine is really only for this summer so I can drive the car and build the turbo motor over next winter.

I replaced all the intake valve seals in this picture, using the air pressure to keep the valves up. The seals that were there were hard as a rock some cracked on one almost non existent.



-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: June 06, 2018 05:49PM

Way to go!! have fun this summer and keep it for a spare!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 19, 2018 03:57PM

Progress update:

All sheet metal has been power coated, lifters were reground (see THISthread), Resealed, oil pan, viton o-rings, new gaskets on rear adapter and on front housing along with seals.

Converted an internal alternator and powder coated, also, made a bypass dummy fuel pump with gage.



Have a few parts I am waiting for to button up the rest of the sheet metal and top cover.

Starting on carb rebuilding in the next issue....

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY



Edited 1 time(s). Last edit at 06/19/2018 03:58PM by toms73novass.

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 22, 2018 04:02AM

I decided to try and relocate the jets in the carbs, had extra bases so if I screwed up I had a back up plan.

I had a 65 carb with a PE valve and used that as a starting point for measuring where to start drilling. (In retrospect I would have moved the location up about 1/16 of an inch if I were to do again, will explain shortly)

Leveled the carb base in the mill.



Located the center location and drilled with a 13/64 drill through the outside and through where jet will be located:



Here is where I would make the change I would not drill as deep with the 13/64 drill, I would drill deep enough to thread for the jet and then use a smaller bit like a 5/32 to break through into the cavity. When I threaded the jet a few of the teeth of the tap cut through into the lower chamber below the carb. I was able to weld it shut. If I was up 1/16 of an inch it also would have been fine.

Next I threaded with a 1/4-28 fine tap, once again not as deep next time.


Then I drilled with a 21/64 drill through the outside and spotfaced the inside surface, don't spotface too deep.



Then tapped the outer bowl with a 1/8 pipe tap for a plug.



Cleaned it all up and inserted jet.



The opening in the jet is actually slightly lower than the opening in where the original jet sat, that is why I would move it up 1/16 next time to give a bit more clearance from the bottom break through potential.

Next is to get a 1/4-28 set screw to fill the old jet location and 1/8 plug.



-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: June 22, 2018 07:44AM

You may just have started a "sideline" business! Most use the '65< PV carbs...

If you can offer this on earlier carbs.... there may be a demand!

Time will tell how well this location performs.





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 23, 2018 05:14PM

Figured I'd give these a try, Nordlock washers, self locking washers. Pretty interesting design if you wish check here.

I used grade 5 bolts with these washers, hopefully the top cover will stay nice and dry.



-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 26, 2018 08:06AM

I made extended vents, probably a bit overkill for my application at this point, but what the heck.

I started with 3/16 brass tubing, because I already had it, copper probably would have been easier to work with.

I filled the tube with sand and crimped the ends.



I heated with a propane torch where I wanted the bend and made a 90 degree bend, had to tap on the bend perpendicular to it with a hammer to keep it from pinching even with the sand.



I then just for good measure, after cleaning out the sand REALLY well, put a solder joint on the inside of the bend just in case there was a unseen crack to make sure there was no air leak.



Here they are installed, they sit flush with the gasket surface and will not interfere with the floats.



I also heated the base of the upper part of the tubes before bending inward.



These as they are clear the intake runner.

The last step was to pot them in with some JB weld just to make sure that the don't change their position with vibration.




-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: June 26, 2018 10:31AM

Now cut out that Duckbill... more flow!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 26, 2018 02:02PM

I Chose the best shaft I had with the least amount of wear, but for piece of mind I also made an o-ring seal setup. I took a few old accelerator pump springs and cut them down, a stainless washer I reamed out and a viton o-ring, had all the parts on hand. I also spotfaced the carb surface so I had a dead flat surface for the o-ring to sit upon.



To retain the screws they should be staked, from the inside. It is important to support the shaft, as I did with an anvil. I shaped an old punch to make a staking tool.




Here it is all assembled.



The carbs are discolored internally, however they are not corroded.I also checked all passages ways are clear and measured both venturi clusters were identical.

Just have to wait for the jb to set fully before I can finish the top assembly.

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 27, 2018 08:51AM

Took some sage advice from steve g. He recommended a bit of lead in on the oring seat so I used a ball end mill to "cup" the o-ring where it contacts the carb body.



Also while going through Bob Helt's book I noticed the replacement seats for the fuel inlet were larger than stock. For 64 on they should be .084 the ones from Clarks measure .097 according to my gage pin.



As a result I set the floats a bit higher (reverse of actual fuel level) instead of 1-1/16 I went with 1-1/8.

If anyone is going to rebuild I HIGHLY recommend the book, even found out high idle on one side need to be adjusted and choke rod adjusted.

Well getting closer to getting this engine fired on the stand!



-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: June 29, 2018 01:38PM

She Runs!



Had a loud lifter noise that I even thought could be a rod confused smiley

Ran for 15 min at 1500-2000.

Shut down, walked away from it out of a bit of frustration.

Came back to it a couple hours later fired it up and in 5 min all was quiet!!!!

Whew....


Now have to do a bit of carb trouble shooting.

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: June 29, 2018 01:41PM

You'll get it!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: July 02, 2018 10:00AM

On to the flywheel. It was a stock one that sounded like a thud then tapping with a wrench, loose rivets...

After taking the flywheel apart I put the friction surface in the lathe and boy was this thing out of shape!!!!

First off the surface that the flexible crank plate attached was not flat it was out by .010 at various positions around the parameter as indicated in red in the picture.



As for the friction surface, that was out by .021 and concentricity was out by .016

After truing all surfaces on the lathe , creating a .022 step and creating a non directional finish on the friction surface. I bolted it together on a fixture I made up. Got it to .0025 contricity.



Next up to take one of my heavy duty pressure plates and cut off the lugs to reduce the weight, basically making it like the lighter weight pressure plate friction surface. But these are made from nodular iron instead of the lighter weight cast iron friction surfaces.

-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: toms73novass ()
Date: July 03, 2018 05:26PM

Took the lobes of the pressure plate with a bandsaw, followed up with the rotary table on the mill.



Here it is all done.



And lastly I static balanced all the parts starting with the flywheel, then the ring of the pressure plate and then the whole assembly. I used some nice abec-1 bearings and took off the sides shield and removed all the grease and replaced with wd40 so they would spin with no effort.

The cross support was leveled with a 10s/2mm level (very accurate).

The parts took forever to stop spinning with the lightest nudge. But this is what you want when static balancing that any little bit of off weight to settle.

You get a pretty good idea if the item has gotten to final balance, when it comes to a stop and doesn't backtrack also the stopping point is random.

I probably put 3 hrs into just getting the balance as close as I could. I think it will be fine with out dynamic balancing.



-Tom


63' Monza Spyder Convertable (in process) MY Build Thread
65' Monza
73' NovaSS 454 Big block
86' BMW 325es
98' Dodge 2500 12v Cummins Diesel with 1200 lb torque!
98' VW Jetta TDI, for daughter
01' Audi Allroad Stage 3 twin turbo

NFCC
Grand Island, NY

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Re: The "mutt" grinning smiley
Posted by: MattNall ()
Date: July 03, 2018 06:46PM

Should be fine!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Current Page: 8 of 9


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