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Author Topic: Thezorn's AAZ rebuild.  (Read 62100 times)

Reply #75January 29, 2011, 12:15:04 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #75 on: January 29, 2011, 12:15:04 pm »
I wish I had, or could find a 5.5 bacause im possitive that is it.
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Reply #76January 30, 2011, 03:26:07 am

macka

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Re: Thezorn's AAZ rebuild.
« Reply #76 on: January 30, 2011, 03:26:07 am »
try a 7/32" if you can find one
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Reply #77January 30, 2011, 07:02:10 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #77 on: January 30, 2011, 07:02:10 pm »
Quote from: macka on January 30, 2011, 03:26:07 am
try a 7/32" if you can find one

Yea tried that. It might have been able to take it out but it was at the point were I could see it almost wanting to strip, so I decided to wait. Im going to Have to see what I can find for it.

Anyways, Here are some pics of the new Intake manifold Ive been building.






Still Have alot of work to do till its done, but its coming. I have domed (half circle) caps for the tubing that should hopefully come sometime this coming week. Let me know what you guys think.
Also, does anyone have a DIY or a guide for rebuilding the kkk turbos, I have a k14 and k24 that I am rebuilding and looking at the kits I have no idea what half the stuff is. I searched but I didnt see anything helpful.
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Reply #78January 30, 2011, 07:15:18 pm

Powered by Spearco

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Re: Thezorn's AAZ rebuild.
« Reply #78 on: January 30, 2011, 07:15:18 pm »
Are those runners going to clear the valve cover?
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Reply #79January 30, 2011, 07:24:36 pm

theman53

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Re: Thezorn's AAZ rebuild.
« Reply #79 on: January 30, 2011, 07:24:36 pm »
I forgot...I didn't loosen mine. I broke everyone except the hard one to get to. I used vice grips and TONS of heat to get that one. Then tons of heat to get the broken pieces out. I replaced them with stainless so hopefully it never happens again. Also much antiseeze added as well.
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Reply #80January 30, 2011, 07:33:07 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #80 on: January 30, 2011, 07:33:07 pm »
Quote from: Powered by Spearco on January 30, 2011, 07:15:18 pm
Are those runners going to clear the valve cover?

Yea about a quarter inch or so clearance. That was one thing I made sure of.
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Reply #81January 30, 2011, 07:53:05 pm

RadoTD

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Re: Thezorn's AAZ rebuild.
« Reply #81 on: January 30, 2011, 07:53:05 pm »
That intake is sweet! I can't wait to see it finished!

Any numbers on the plenum sizes/slot area/runner lengths or did you just sorta wing it?

And any possibility of dyno's with both? ;)
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Quote from: R.O.R-2.0 on July 24, 2011, 11:57:45 pm
enough boost is when you have 3 dimple marks in the hood from the valve cover nuts..  ;D
Reply #82January 30, 2011, 08:17:13 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #82 on: January 30, 2011, 08:17:13 pm »
Quote from: RadoTD on January 30, 2011, 07:53:05 pm
That intake is sweet! I can't wait to see it finished!

Any numbers on the plenum sizes/slot area/runner lengths or did you just sorta wing it?

And any possibility of dyno's with both? ;)

Pretty much winged it. The smaller plenumn is a 2" tube, and the bigger (main plenumn) is 3". The runners are 1 3/8s ID. Pretty much made them the same length as the orignal intake flange. The slot is about 1/2" wide and runs almost the full length. Now that I look at it I should have made the slot Tapered to the end of the manifold, but i guess we will see how this works.

A dyno would be awsome once the car is all back together, and im sure if I ever did one I would try with a stock intake also to see the difference. Only problem is that the closest one is, Im guessing, 7 hours away in Prince George :(
Ill be working on the intake some more tomorrow so Ill keep you guys posted.
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Reply #83January 30, 2011, 10:11:16 pm

RadoTD

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Re: Thezorn's AAZ rebuild.
« Reply #83 on: January 30, 2011, 10:11:16 pm »
Come to Vancouver, I'm sure someone will have somewhere for you to stay. We can dyno our cars together! :D
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Quote from: R.O.R-2.0 on July 24, 2011, 11:57:45 pm
enough boost is when you have 3 dimple marks in the hood from the valve cover nuts..  ;D
Reply #84January 30, 2011, 10:22:58 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #84 on: January 30, 2011, 10:22:58 pm »
Quote from: RadoTD on January 30, 2011, 10:11:16 pm
Come to Vancouver, I'm sure someone will have somewhere for you to stay. We can dyno our cars together! :D

That would be awsome. Ill make sure I let you guys know if I come down there this summer
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Reply #85February 02, 2011, 05:20:13 pm

Gizmoman

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Re: Thezorn's AAZ rebuild.
« Reply #85 on: February 02, 2011, 05:20:13 pm »
Well, I gotta say I feel for you. I am new to the AAZ (83 Vanagon with a 1.9 IDI) but spend an hour or so every night reading various articles on this forum. I guess that makes me a "lurker" but I'll chime in when I can add something.
Reading of your plight makes me pay close attention to all the talk about spinning the timing belt sprocket for sure. Maybe I should consider the same for mine. I have no idea as to what the PO did or didn't do but I think I'll check it now - for sure.

I must commend you on your stamina and your willingness to spend your valuable time keeping everyone in the loop.

Big thanks!

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Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost
Reply #86February 04, 2011, 11:45:08 am

arb

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Re: Thezorn's AAZ rebuild.
« Reply #86 on: February 04, 2011, 11:45:08 am »
Nice build and I love the aluminum welding. What type of welder to you have ? Why the double plenums ?
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Reply #87February 04, 2011, 01:16:18 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #87 on: February 04, 2011, 01:16:18 pm »
Quote from: arb on February 04, 2011, 11:45:08 am
Nice build and I love the aluminum welding. What type of welder to you have ? Why the double plenums ?

I actually use a TIG welder at the local college, I am a welder by trade and am good friends with the intsructors so they let me use the stuff up there. Its a miller tig, but im not sure what model it is. Its an awsome machien though. Not really sure why I did the dual plenums, just sorta felt like it would work nice. I have more updated pics Ill post up later. Ended up re-doing the top half, so it looks alot cleaner, ill post them up later on today.
Right now im off to the machine shop to have them tell me there still not done with the block and the crank...wish me luck.
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Reply #88February 04, 2011, 02:56:38 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #88 on: February 04, 2011, 02:56:38 pm »
Here are the pics of the pretty much finished manifold. I still just have to weld a piece of 2" tubing onto the intake and and put the 2" cap on the opposite end, then it will be done.
Back

Front

Slit, I went with a small taper this time.

Cap


Then Ill have to clean it up, and make it look nice. Surprisingly the machine shop isnt done! even though they have had it all since before the new year...yay.
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Reply #89February 06, 2011, 07:18:28 pm

Thezorn

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Re: Thezorn's AAZ rebuild.
« Reply #89 on: February 06, 2011, 07:18:28 pm »
Does anyone have a copy of instructions or even a DIY for that matter for re-building the kkk k14 or 24 turbos? I bought a kit off a local guy but I have no idea what most of the little things are for :P
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