The van passed its MOT with flying colours today! No need to say much more than that! :o) A good day for L2S!
Good news at last! The engine is complete and now needs some serious miles under its belt BEFORE we head off on the road to Sydney. A rebuilt engine needs to be ‘driven in’ and then re-tuned and given several oil changes. Hopefully we should be able to do about 2000 miles in the van before July, thus ensuring that the engine is in perfect working order before we leave. During this time we will be careful to keep the engine revolutions below 3000rpm in order that no stress is put on the motor.
The van will now complete an MOT and be taxed. Action pictures to follow.
Nothing is ever as simple as it seems. The best laid plans of mice and men… Which ever sayings you prefer, the fact remains that the toast doesn’t always fall butter-side up. Sometimes it’s a sticky wicket and you’ve just got to play the dead bat and get yourself in. Having thought that the engine would be finished yesterday evening, it’s taken a further day in the workshop to get within touching distance of having a working van. I’ll explain…
We’d been puzzled as to why the engine wasn’t rotating freely in the van when it did outside of it. This meant the starter motor couldn’t turn the engine over as the flywheel wouldn’t turn through 360 degrees. After much puzzling and thinking we somehow hadn’t got the engine in correctly (or had fitted it at an angle somehow), we realised that the precision balancing had meant that two nuts were protruding further than usual from the flywheel. These nuts were then locking against the inside of the gearbox casing and causing the engine to stop turning. To fix this problem, Lee got grinding.
We took the engine out, ground some more of the gearbox, put the engine back in, found it still didn’t turn 360, took the engine out, ground some more of the gearbox, put the engine back in… On the third attempt however the engine turned full circle! The delight was obvious. Much thanks have to go to Lee for his patience and Ricky and Tom (VW enthusiasts) for taking time out from their own projects to help with shifting the engine in and out of the van today.
Tomorrow should be a case of simply putting the starter motor, fuel line and tinware back on. However, as I’ve learnt this week, never expect things to run as smoothly. I won’t be holding my breath, but should the van be running tomorrow I’ll be the happier than the Easter bunny! It’s been a long and frustrating week at times (and I seem to have spent most of my time in Lee’s workshop) but it’s been good fun too and I feel I’ve learnt a lot more about the van’s mechanics at the same time.Cheers Lee.
Fingers crossed for tomorrow folks. Have yourselves a Happy Easter.
Well, we didn’t hear it running, but today was a successful day for the London2Sydney household. After picking up some fuel hose and T-bar, myself and Andy got over to LA Performance for about 9am. With Andy having to leave and catch a flight back to the States a little later, we only had a little time left to work on the engine together. Even so,it gave Andy enough time to get his hands on an angle-grinder and get the grips on the heat-exchangers to fit snuggly to the engine block.
After much pruning with the angle-grinder, we finally managed to fit the heat-exchangers (and then had to take one off again as we forgot to put on the engine bar). The studs which protrude from the engine casing can be very fragile and we were extremely lucky that they stayed firm. Lee told us that had they broken, the whole engine would have had to have been stripped again! Not what we would want to hear!!
Once we’d fitted the fuel Andy’s last action before heading for the airport was to help lift the engine off the work bench and onto the trolley jack. Needless to say it was incredibly heavy and needed all three of us. Simply pushing it off the bench and letting gravity do the hard work was unfortunately not an option….
With Andy gutted at having to leave with the project so near conclusion, Nick carried on the good work. Once on the jack, it was a matter of jacking the van up to allow the engine to be rolled under the engine bay and then jacking the engine into the van. This is not as easy as it sounds. For anyone who has never put an engine back in a VW (or any vehicle for that matter I guess), it takes a lot of wriggling and pushing to get the crankshaft and clutch aligned with the gearbox. With Lee pushing and jiggling the engine and Nick operating the jack, we eventually managed to get it in the right position.
Three hours or so later, the engine was finally fitted. The engine bar had been secured (after an inital problem with one of the brackets) and Nick had bolted on the remaining tinware. (Tinware, as you’ll remember from previous posts, is the metal which funnels air over the engine). The nastiest job had been fitting the fuel line. Even with the line clamped as tight as possible, lying under the van and a removing the plug to fit it to the pump means you get petrol dribbling down your arms. Nice! Here’s the mole’s eye perspective…
With Lee putting the final touches to the van today (tuning and fitting the new exhaust back-box), Squiffy should be ready to come home on Thursday evening. I can’t wait!
Come back for more news on Friday!
An early start saw us at L.A. Performance once again to begin the final preparations before Squiffy’s engine would be ready to be reunited with Squiffy herself.
Nick and I set to work sorting through the jigsaw of tinware pieces (exchanging many quizzical glances and shrugs–it’s quite an exercise in spatial reasoning!). Meanwhile, Lee put the final touches to the beautifully prepared long block (the heart of the engine).
Only one thing stood between us and Squiffy with a purring engine at the end of the day, and that was… a badly fitting oil pump! Unfortunately, despite hours of grinding, hammering, blow-torching and cut fingers, nothing would make our oil pump fit properly to the engine, until we eventually had to swap the part out for another which, mercifully, fitted perfectly.
It was starting to look like we wouldn’t be able to reach our goal of having the engine back in the van and running by the end of the day, but after a quick lunch, things began to pick up and progress was rapid. On went the rest of the tinware, the engine’s fan and the very business-like carburetors which Lee then carefully set-up.
Despite valiant efforts, the absence of a few of the key components of any good engine (erm spark-plugs being one!) meant that we had to call it a day for today. But we’re not beat!
Will Lee and the London2Sydney team be able to get the engine back in the van before Andy’s 4pm flight back to the US…? The challenge begins 0900 hours, L.A. Performance’s workshop. Check back tomorrow to find out!
It’s been a successful weekend. Andy’s been back from America and we’ve worked solidly on preparing the ‘tinware’ for the new engine. For the uninitiated, the tinware are the sheets of metal shrouding which to funnel air over the engine – thus creating the ‘air-cooled’ effect.
Due to Squiffy’s previous oil leak, much of this shrouding was absolutely covered in oil and several years of general dirt and gunge. Armed with some GUNK (http://www.gunk.ca/), several cloths, some surgical gloves, some soapy water and some black spray paint, Andy and I tackled the tinware with a vengence. Let me tell you that there is nothing more satisfactory that taking a piece of dirty metal and restoring it into a glistening example of VW precision engineering. Erm, is there?
And so tomorrow we head for LA Performance, ready to bolt the tinware onto the engine and put the engine back into Squiffy. Watch this space! Tomorrow could be a momentous chapter in the L2S story! We’re excited!
Meanwhile, a spot-the-difference competition. Answers on…an e-mail!