Sweet project, why did you make the fly cutter so big though lol?

I would've made a tool holder just bigger than the spindle and put a longer tool in....afterall its a single point tool so shouldn't deflect too much, if at all.

Have you ever skimmed anything before? No offence...

You need to be able to pass over the object in one pass, No going back and forth over already machined surfaces.

This means you don't get any track lines or high spots. Also, the bigger the radius of the cutter the better. Milling always leaves cutter marking on the work-piece,

The bigger the radius of the cutter, the closer the markings are to a straight line. So yeah there was a reason I made the disk as big as I could lol

Ill get some pictures up soon.

Yeh, I do all the time, although I work on a Jig-borer so it's alot slower than doing it using a CNC mill.

Was just saying, I have to flycut fixtures all the time being an operator on a jig-borer and the fixtures have to finish up within a few microns parallel to the table. I just use one tool holder and change the length of the cutter for the area that needs to be cut. Easily skim a head in one pass.

But whatever, if you feel thats best then props to you, just seems abit over-engineered for the task!

I think you might have some trouble with the carb and air filter hitting the bonnet with all the extra height of the adapter and ISO block, I did with mine and I didn't have the ISO block, just something to consider :)

Looking good otherwise max

Yeah i did think that. The air intake I'm using it pretty flat and goes off the to side. I may get away with it.

I think i will be using some bonnet raiser's also

Anyone know what the hell that stuff on the other cylinder head is? And why its there?

Just looks like small carbon deposits, engine it was installed on could have been running a bit rich, thats all.

Thanks for that mate,

The thing is though, the engine was never started and the carburettor wasnt functioning properly regarding fueling.

Oooh I'm excited! Top work as ever max ISO blocks look sweet! Black was deffo the colour for the head.. looks awesome. Any news on the "spare" cylinderhead?

He lives!! , Haven't heard from you in ages fella lol.

Yes the spare head is yours if you want it. Its a 1272cc mk3 head so no hole for the fuel pump.

Can skim it for you , what else would you like?

Note that theres two of the iso blocks?

Haha

Haha, sorry chap been working loads and moving house. Only got tinternet sorted this week. Handy the heads a mk3 one, save messing about! We're square on the adapter plate and iso block arn't we? If you work out how much you wan't for the head plus a skim and a bit of port fettalage and let me know.

Yeah were square on the adpater and ISO block. Pm me regarding the head mate.

She waits behind the rocco....

Finally the DMTL set-up is completed.

Finished building it all up after work tonight, Consists of:

P+P MH inlet

Aluminium adapter block

ISO Block

32/34 weber DMTL

Pics:

This leaves the engine pretty much finished off now, Just all needs mating with the parts from the 1.05 AAU like alternator and waterpump etc.

Can't wait to finally get it in and see if this hard work has paid off.

M

Great work as always! Looks top.

Did you port match the inlet? I'm deciding whether to do mine, been told recently that it's not a good idea, for 1) the port shape should be tapered from the valve throat to the entrance at a constant rate, enlarging the mouth of the port can interupt this and cause the velocity of incoming charge to slow, and 2) the slight step between the manifold and head helps prevent gases reverting into the inlet manifold as the piston rises whilst the inlet valve is still open.

I'm not really sure if this will apply to these heads, as that info isn't gonna be true for all engines and I know you did it on your last engine... gains to be had? Bit of a grey area for me as I've not really looked into it before.

Thank's for the info jon,

I haven't Port matched the inlet to the head as such, Just cleaned up the outlet tracks of the inlet manifold. Originally there was a sharp step all the way around them, I just smoothed this off and cleaned them up nicely.

If your doing some work on the inlet, Just make sure everything is nice and smooth, Wouldn't bother enlarging anything like track diameter.

With me using a carburettor, I need the tracks to be moderately small in diameter anyway, I'm sure you know the small the diameter, the high velocity of the gas, which i need to for good fuel atomization out of the jets in the venturi's.

However with you using injectors , your fuel is atomized pretty much the same at whatever air speed so small diameter tracks isn't as important.

This is why if you take the inlet manifold's from the two 55bhp 86c engines (The MH what I am using, and the AAV in your mk3) , the track diameter on the injection AAV is much bigger than the track diameters on the MH manifold. I bought both of them when i was wondering which one to use, settled for the MH in the end.

M

Sounds good man...

Nah I'm not gonna work the inlet mani at all, just used the die grinder to smooth off the insides where it was welded!

Ah that's interesting, never knew the manifolds were carb/ injection specific!

Think I'm gonna have to do some more time on the flow bench to be honest, get a spare head and manifold and find if there's gains to be had from this port matching business! I'm sceptical...

Yeah they are very different,

I think this is the correct way around, but on the AAV inlet manifold, All 4 runners join to the centre plenum chamber where the TB sits, But on the MH inlet manifold, there is only two big runners that come off the plenum chamber, then them two runner split into two again and these become each one of the 4 runners if that makes sense?

Also the AAV inlet has one big hole for the one injector, whereas the MH inlet has a long oval shaped inlet for the double throat carburettor that bolts on, You can see what i mean about this on the pics of my MH inlet.

Should be finished soon though, hows your welding going on lol?

M

Yeah I follow! Interesting, bet VW spent bloody ages designing those!

Got a deadline for it to be finished by?

Done it all now, been scrounging around for a new radiator at a few scrappys but had no luck.

Gonna have to order a brand new one tomorrow

I have a rad mate, Its in al right condition as well.

Not perfect obviously and has some over spray on it but I'm sure its perfectly useful.

Yours if you want it.

M

That DMTL looks like it comes from a 2.1/2 or 2.5 Landy rather than being a normal DMTL.

Edited 7 January, 201115 yr by goose

That DMTL looks like it comes from a 2.1/2 or 2.5 Landy rather than being a normal DMTL.

It is from a landy. I got both exploded diagrams infront of me when i was lookign for it and the only problems they offer is the two soleniod shut offs, These just need to be wired together, Also the adapter plate is different.

Looking nice max

Are you gonna be hooking up the electric preheat plate? Just a thought as I'm not sure whether to bother.

Also what paint did you use on your cylinder head?

Just some high temp stuff from halfrauds mate,

Yeah ill be hooking it up, Might as well have it for warm up etc.

M

Just ordered these:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...T#ht_2296wt_905

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...T#ht_2514wt_905

Hopefully look pretty swanky, First in the scirocco, then the polo!

M

It was finally good enough weather this weekend to pull the old engine out :-D

Got these for cheap as well , 8j & 7J , in a bit of a state as you can see.

They needed 2 new tyres however.

Also, here's pic's from the rally experience i went on a few weeks back, There's nothing like it, By far the most fun you can have on 4 wheels.

Need to get cracking with putting in the 1272 now...

Are they essentially golf GTI steels? (orig 14 x 6J ET 38). If so you are a legend.. good luck with hiding the 203.2mm of width though! I really want a set of 14" mk3 golf ET45 steels wide'need an inch for my G40.. one day.

Rally experience looks awesome! Where did you do it?

That steering wheel looks the shizz :)

Are they essentially golf GTI steels? (orig 14 x 6J ET 38). If so you are a legend.. good luck with hiding the 203.2mm of width though! I really want a set of 14" mk3 golf ET45 steels wide'need an inch for my G40.. one day.

Rally experience looks awesome! Where did you do it?

They are my friend.

Yeah the width may be a problem, but it will only take abit of arch work.

The rally experience was amazing, and it was at silverstone.

M

That steering wheel looks the shizz :)

Thats on my rocco thread lol, Not my polo!

Cheers though!

Some more updates!

Polly started the day looking like this:

Need the original gearbox for my new 1272 so got to work taking it off, obviously had to go through the crankshaft alternator belt pulley first etc:

Engine first thing in the morning:

Was hit head on straight away with a problem, The bolts holding on the alternator pulley were completely rounded off, obviously the first 3 came off without a problem using the hammer in a torx bit technique, The last one wasn't having any of it, Tried the torx method and ended up ripping the teeth off on the bit, leaving me with a completely round hole in the bolt head, Only one option was left...

The little bitch came out first swing of the hammer. Then took the box off, what would you recommend re-newing? apart from the clutch.

The parts were stacking up..

Stripped block...

Gearbox, cleaned it as well as i could with carb & brake cleaner:

Painted it, mostly. Had to be black....

Left that to dry, Got on with something else i wanted to do.

As you can see the rear of the car is pretty much my parts bin at the moment, But its coming along nicely.

Need to get the gearbox and new block mated together and put back in the nice cleaned/polished bay. Then add all the ancillaries etc.

Also had a test fit of the new wheels, 14x8" rear banded golf GTI steelies and 14x7" on the front....

Rear:

Front:

Excuse the massive arch gap, the fronts only down 40mm at the moment with no engine in.

Also excuse the ridiculous colour, tyre choice and the fact that they're filthy.

Gonna be having them sand blasted, etch primed and painted in a nice silver, then lacquered to hell and back.

have started on stripping, skimming and P+P'ing my spare head for "randombadger"

some pics:

Hope you like!

M

Edited 18 February, 201115 yr by MaxMax

sweeeeeeeeeeeeeeet looking good max !