Date: Fri, 9 Jul 1999 15:03:52 -0400
Reply-To: Bulley <gmbulley@BULLEY-HEWLETT.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Bulley <gmbulley@BULLEY-HEWLETT.COM>
Subject: motor rebuild update
Folks-
Just got back from T-Hoff, in Raleigh, the folks doing the machine work on
our 1982 Westfalia Motor. For those who are interested in such, here are
the details.
The balancing of all the parts is now at zero grams across and along the
crank, including the fan, flywheel and pressure plate. Even though our new
counterweighted crank was (nearly) zero to start with, the flywheel was 3
grams off, and the fan was 8 grams off.
The rods are a matched set now, and balanced end to end. Three of the rods
were close to spec (off by .75 grams here or there) One of them was
obviously from another set, and was WAY out.
The alignment on the block is perfect, and they have cleaned the entire
block, and bead blasted the outside (aesthetics, mostly).
The pistons and cylinders were trashed. Ordered a set of MSHP 96mm
pistons/cylinders...their website claims 25-30 hp increase: (From their
site) "BOLT ON HORSEPOWER!!!
NOW YOU CAN ADD 25 TO 30 HP
WITHOUT SPLITTING YOUR CASE -- Street and track tested. Super strong
hypereutectic pistons. Flat top with valve relief for performance cams.
Slipper skirt can be used with up to a 78.4 stroke with stock rods without
clearancing cylinders. Heat/corrosion resistant coating. Compatable (sic)
with standard fuel injection. Cylinders are torque plate honed for in-use
roundness. Plateau finished for pre break-in. Available for both 66 and
71 stroke engines.
96MM PISTON & CYLINDER KIT $ 349" (end of quote)
I am not holding my breath, betting on +30 hp, but it should be a bit
punchier. Since we are adding two auxiliary oil coolers, 40-feet of copper
oil line, and an oil thermostat, I am not worried about the little extra
heat from the 96's. The pistons will be balanced when they arrive.
The heads were close to being trashed. They had to do some back-fill
welding to fix two dropped seats and a couple burned spots. We *almost*
used one as a boat anchor, and the other as a door stop, but Kerry and
Jason at T-Hoff assured me they can be good as new...so they are still
working on them. New guides, seats, valves, and a slight flycut to smooth
things out.
We get everything back from the shop on Wednesday or Thursday, and that is
about when the pistons will be here, so it may be a late night Thursday and
Friday. Then we can throw it all back in the van on Saturday/Sunday.
In the mean time, I have all of the copper lines installed under the van,
and will install the coolers up front in the coming evenings. I won't mount
the oil filter relocation or the thermostat until the motor is in place. I
have some ideas of where I want to route things, but want to measure twice
and cut once.
Will keep you posted.
G. Matthew Bulley
Bulley-Hewlett & Associates
www.bulley-hewlett.com
Cary, NC USA
888.468.4880 tollfree