1.6 IDI Waterjacket Improvement

[saurkraut]

PS - I had what I believe to be a breakthrough discovery for successfully using the 1.9TD headgasket on a 1.6 solid lifter block! (but that is the topic of another thread.  )

Hey Jake, What's the breakthrough!  Please share!

[saurkraut]

PS - I had what I believe to be a breakthrough discovery for successfully using the 1.9TD headgasket on a 1.6 solid lifter block! (but that is the topic of another thread.  )


Inquiring minds want to know! :wink:

[saurkraut]

Yup, racing is very time consuming.  Been there, done that.

This topic had migrated to page 2 and I just wanted to keep it near the front.

I recently did a metal head gasket on my frau's 16v, and it held up to her normal instrument scan.. lost the waterpump belt, and her first indication of the issue was steam escaping the seams of the hood.  Even melted the plastic water spigonts on the head.  That was over a month ago, and the darn thing is still keeping its water, oil, and combustion gases where they belong.  So far, so good.  If/when it does fail from this abuse, I'll change it.  But it clearly shows that metal head gaskets are tough!

Therefor, metal headgaskets on the 1.6 mechanical is big stuff.  if there is an eligant way of doing this, two heads in my fleet will be off within hours, and, I imagine, many more from this group as well will follow.

Just trying to maintan visibility.

[fspGTD]

Hey guys - I appreciate your interest and patience during this great but oh so busy time of the racing season.

Regarding the solidlifter headgasket mod... I am still testing it to see if it actually works.  When the jury is in, I'll post up here some details about the procedure.  At this point I'm not sure that the method is reliable.

[fspGTD]

Well, what do you know, but it looks like it still leaks.  It's just like when I've tried to use this gasket before; where it holds pressure fine when hot, but allows very very slow and minor leaks when the engine has cooled off completely and the head has relaxed pressure on the headgasket, then the coolant can "weep" out.

[saurkraut]

Briefly, did you try somthing different this time?

[Mark(The Miser)UK]

Well, what do you know, but it looks like it still leaks. It's just like when I've tried to use this gasket before; where it holds pressure fine when hot, but allows very very slow and minor leaks when the engine has cooled off completely and the head has relaxed pressure on the headgasket, then the coolant can "weep" out._________________
Jake Russell

What happened to that mismatch I underlined? Years ago I seem to remember blocking a surplus water hole on a head where it had corroded with wood which swelled and sealed. Can't believe that was 25+ years ago  :cry:

[Kudagra]

Jake, if the route you are trying to take is the silicone one I would suggest the Permitex Grey. Its nasty strong stuff. Or the stuff we use at Bobcat to install Deutz engine oil pans. Same nasty grey stuff (and about 50bucks a tube)

I think its the same stuff Detroit uses for Series 60 Pans.If You like I can send you a half tube if you want to try it.

I was thinking... Would it be better to lay down some soft copper wire in the same areas as the silicone? Or maybe some Solid core solder. Not like you are using this as a cross county car.  If it works..

[Audi80]

I installed a 1,9 metal gasket to my 1,6 solid lifter engine. I used a piece of 2mm rubber to block the hole. Seems to hold good, no leaks so far (~600km hard driving)  

[ODwyerPW]

Could you use the 1.9 metal headgasket as a template to put the steam passages in both the head, block and the 1.6 solid lifter stock headgasket.  I know you folks want to use the metal one.  However, can I drill through the stock 1.6 solid lifter headgasket to accomodate the steam passage mod?

[ODwyerPW]

I guess if you have the hydraulic block and head, then you can perform the block, head mods for the steam passages and not worry about the mismatch you are seeing with the solid lifter setup.

[subsonic]

Getting my 1.6 hydro block bored this week.  Thinking of doing this mod as I am adding a 1.9 head.  Pictures in the posts seem to have gone dead.  Anyone care to refresh?

[theman53]

Flatout Gaskets Copper Cylinder Head Gaskets
Great sealing head gaskets.

Flatout Gaskets copper cylinder head gaskets are made with an exclusive rubber-coated copper process. The base metal is 100 percent soft annealed copper, and the specially formulated, high-temperature rubber coating is designed to seal coolant and oil.


I saw these and keep wondering if someone makes them for VW, or could they be custom made for a $$$$ price? I have also heard they make this sheeting in copper in perfect thickness that you can cut your own. It is just an idea that I had, but it might help somone who is further along in this process than me. I hope I didn't just open a big can of worms and made more questions than answers. :lol:

[jtanguay]

Flatout Gaskets Copper Cylinder Head Gaskets
Great sealing head gaskets.

Flatout Gaskets copper cylinder head gaskets are made with an exclusive rubber-coated copper process. The base metal is 100 percent soft annealed copper, and the specially formulated, high-temperature rubber coating is designed to seal coolant and oil.


I saw these and keep wondering if someone makes them for VW, or could they be custom made for a $$$$ price? I have also heard they make this sheeting in copper in perfect thickness that you can cut your own. It is just an idea that I had, but it might help somone who is further along in this process than me. I hope I didn't just open a big can of worms and made more questions than answers. :lol:

copper is a great sealer.  but people have talked about coppers expansion rate, and that being the issue

[subsonic]

I have my 1.9 HG on hand.  I was planning on using it but was thinking of doing the block mod.  Any one have the pictures from the front of this post saved?