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Date:         Wed, 8 Nov 1995 00:36:12 -0600 (CST)
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         dakhlia@wuecona.wustl.edu (Sami Dakhlia)
Subject:      rebuild: finishing touches

This should be the second to last report on the top-end rebuild of a '75 bus, tomorrow being the big day.

I separated the rehoned barrels and the pistons one more time, again cleaned them all in hot, soapy water, this time VERY thoroughly, until smooth to the touch. Realigned the rings and fitted the pistons back into their respective barrels, this exercise being much easier now that I'd done it 8 times already before... The friction was now considerably less, so I obviously *lied* when claiming that the p/c's had been well cleaned in a previous post.

The heads still had aluminum shavings in all hooks and crannies, including under the valves (!), and took a while to be cleaned. Also the cylinder head temp sensor hole was not tapped with care and had burrs in it, which is why the old sensor didn't fit. And finally, I also noticed that one stud at the exhaust ports was missing. So back to the machine shop... :(

After that, things went very quickly: basic engine got put together on Sunday and yesterday I added all the accessories. The story goes much like Joe Fournier's and I also kept working at it until 2 am both nights. This morning, a friend came over and helped me carry the engine from the basement to the parking lot, where the engine got installed back into the bus. It took us about two hours and it was not entirely easy, but nothing worth e-mailing the list about.

Tomorrow, hoses and wires will be hooked up, the whole exhaust system (including heat exchangers) must go on, oil be added, and a few other misc. things. And then.... fingers crossed.

-- Sami ('75 Westf.) dakhlia@wuecona.wustl.edu http://wuecon.wustl.edu/~samid/


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