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#45 by brownni on 01 Feb, 2014 08:09
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I have a new head. It is at the machine shop now getting checked and cleaned up.
Turns out the engine has been rebuilt at least once before. The pistons are all 76.98mm diameter which, according to the bently, is the repair stage 2 oversize. It really put a damper in my plans because I had ordered parts based on the assumption that everything was stock sized. Now I am having to wait on new rings to get here and I need to make sure that I don't have to order oversized connecting rod bearings as well.
I guess I should just be thankful that disassembly has gone well.
I am off to do some honing. Mark, I was tempted to use your waterbottle hone - but I caved and got a ball hone instead. -
#46 by brownni on 01 Feb, 2014 08:43
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also - does anyone know the thread pitch on the 11mm head bolts? I want to get a tap to clean out the bolt holes.
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#47 by TylerDurden on 01 Feb, 2014 09:16
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My gauge tells me 1.5mm.
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#48 by Mark(The Miser)UK on 01 Feb, 2014 12:31
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I have a new head. It is at the machine shop now getting checked and cleaned up.
I've found some really interesting info on honing/deglazing that actually kind of cooberates some of my honing premises. It also goes on about a technique called Superfinishing. Apparently invented by some two-bit little company over seas... Wait a minute... rereading I see they were called Chrysler of America.... Never had anything of theirs, unless my 1970 Vauxhall-Bedford CF is related
Turns out the engine has been rebuilt at least once before. The pistons are all 76.98mm diameter which, according to the bently, is the repair stage 2 oversize. It really put a damper in my plans because I had ordered parts based on the assumption that everything was stock sized. Now I am having to wait on new rings to get here and I need to make sure that I don't have to order oversized connecting rod bearings as well.
I guess I should just be thankful that disassembly has gone well.
I am off to do some honing. Mark, I was tempted to use your waterbottle hone - but I caved and got a ball hone instead.
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#49 by Mark(The Miser)UK on 02 Feb, 2014 17:25
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easy as
745 thanks for the interesting link... Actually 1.6 heads are becoming rare over here as we become flooded with TDI. More AAZ's than 1.6's on Ebay now. Mind you Brownni's 11mm head is a rare beast, especially to have survived 2 rebores!
http://forums.tdiclub.com/showthread.php?t=175661
but unless you have a rare or special head, why?
I've found something too. MIG Al seems quite possible on sheet if heatsink used.TIG clearly preferred given a choice. Not much penetration required on that one head crack, and filling head with water would probably protect it.
Strangely I suddenly thought of the possabliity of MIG brazing. I'd never heard of it, but looking in the margin low and behold he'd done it!
http://www.mig-welding.co.uk/learning-mig.htm -
#50 by 745 turbogreasel on 02 Feb, 2014 17:46
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Survived being a relative term, and the initial incident may have scored the bore bad enough to require 2nd OS right off the bat.