Date:         Thu, 20 Jul 2000 18:44:33 -0500
Reply-To:     "Mark B. Magee" <condor2@flash.net>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Mark B. Magee" <condor2@flash.net>
Subject:      Re: Performance Wasserboxer: Fact or Fiction
Comments: To: Wolfvan88@aol.com
Content-Type: text/plain; charset=us-ascii

Robert,
What was the approximate cost of your parts and machine work used in this
rebuild? Sounds super, I may try and replicate.
Regards
Mark Magee                                                90 Carat
Kemah TX USA
John 14:6

Robert Lilley wrote:

> Sean,
>
>  For reliable HP increase this is what I have done.
>
> Add counterweights to the crank- reduces crank flex and doubles bearing life
> Add a racing crank spacer
> Fully balance ALL rotating parts
> Rebuild rods lower end, re-bush and balance
> Have WebCam regrind your cam to #91- increases top end power
> Add solid rocker shafts
> Add 1.25 ratio rockers: increase bottom end torque
> Add Rhino swivel rocker tips: eliminated valve guide wear
> Add Cromoly cut to fit push rods
> Add Cromoly valve spring retainers
> Have 3 angle cut on valve seats and 2 angle cut on valves.
> Blue print a new stock oil pump: match the ports to the engine case:
> increases oil volume.
> Add a DynoMax Super Turbo muffler: It reduces back pressure (too much of a
> reduction causes the engine to LOSE low end power) It fit in the stock
> location with minimal modifications and it is QUIET at 80 mph. (I had a bug
> with a loud muffler and after a long trip my ears were ringing, now with a
> DST after trip my ears do not ring)
>
> Match port the intake, exhaust.
> Clean up head intake and exhaust ports- you can increase size slightly- (but
> the larger you go the less low end power you have)
>
> Clean ALL parts at least four times with the last with dish washing soap and
> spray with WD-40 and wrap in wax paper until used.
>
> THE number one reason rebuilt engine DO NOT last as long as new is because
> the engines were not properly cleaned.
>
> Apply some type of aluminum protector to the heads to serve as a barrier to
> corrosion.
> I chose ceramic coatings to add a thermal barrier also.
>
> All the changes will give you @ a 30HP+ increase.
>
> You can add the ECU chip at the end if you want a bit more power.
>
> I also added a South African 5 speed tranny.  It is a bolt in, requiring only
> a shortened front mount. I am using the stock linkage and simply push down
> and pull back for first.  I like where first is because you can get to first
> and reverse quickly to rock your van out if you get stuck, I did...  The
> gearing is well suited to the power band of the engine.  In fourth I can go
> to 75 mph if needed for passing.  I would not change the ratios.
>
> I know it all works because I am driving it.
>
> Robert