Date:         Mon, 8 Jan 2001 23:49:27 EST
Reply-To:     Wolfvan88@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Lilley <Wolfvan88@AOL.COM>
Subject:      Re: Engine swappers: How low can your engine go and keep you
              going?
Content-Type: multipart/alternative;

<<Just curious... what is the solution to which you refer.  I'm at 180K on 
the original heads but am always looking for any clue that will make them 
last forever. >>

I started with the AMC heads and changed the Italian valves for German 
valves.  The AMC has a higher aluminum content in the alloy to make them more 
resistant to corrosion.  Added some mild porting and a racing valve job: 3 
angle on seats and 2 angle on valve. Stronger Cromoly valve spring retainers, 
stronger racing valve keepers. Match ported the intake system and exhaust 
system.

I applied (Swain Tech did the actual coatings) a non-corrisive thermo barrier 
ceramic coating to the sealing surface of the head (actually the entire face 
of the head including the combustion chamber) to serve as a barrier to the 
pressure corrosion where the rubber gasket meets the head surface.

My thinking was to put something between the head surface and the gasket to 
prevent the corrosion from starting.  The added plus is that the thermo 
barrier reduces the heat that the rubber gasket gets during running 
prolonging the service life.

I also applied the ceramic coatings to the entire exhaust system, the exhaust 
valve radius, exhaust port and piston top to reduce the radiant heat escaping 
from the engine.  This keeps the exhaust gases hotter and increases the 
exiting velocity, increasing flow of the exhaust gasses out and increasing 
the intake gases velocity into the combustion chamber.  Thus giving an 
increase in power.  The rubber parts and FI parts have the heat they normally 
absorbs reduced to increase the service life.

After an hour run in 95 degree heat, the alternator is warm and I can place 
my hand on it and not get burned.  Before it was too hot.

I have done a lot of other things to increase the life of the engine, 
increase power and improve mileage.  I went from 18 mpg to 22 mpg with an 
increase in power.


Some other improvements:
Counterweights added to stock crank
Lightened flywheel
Full balance
Pauter aluminum roller tip and 1.3 ratio rocker arms
Cromoly cut to fit push rods
Aluminum valve covers
Quad tip platinum plugs
Digifant 022D ECU power-chip upgrade
Super Turbo muffler
Drop in K&N airfilter
Special German coolant
Racing spacer
Racing clutch bolts
Welded clutch shaft
Five speed .457 South African transmission



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