New heads and exhaust finally installed

[jgerock]

After many delays (work and other projects), I finally got my engine back in the car today.  It has new CB 044 CNC round port heads, port matched manifolds and Gene Berg Merged heater/header exhaust.  Hats off to Al Craig of Gene Berg who helped me with the exhaust purchase and also the quick shipment of some new linkage rods.



Car will be put up for sale soon to finance another vehicle purchase.

[jgerock]

More pics added. 

Car only has about 1800 miles on it since I finished it in 2004. 
KEP 1700 lb. pressure plate (still looks brand new)

GB 104A/Centerforce dual-friction disc (great for the street)

Transmission

New oil cooler and seals

Recommended plugs for CB044 heads - you must have a thin-wall 18mm deep socket for plug changes with the manifolds.  Regular spark plug sockets (13/16" and 5/8") will not fit on these small plugs.

Starter solenoid installed in 2003 - no issues with starting.

[John P]

Looks great - what are the specs on the engine?

BTW, I bought one of Berg's earliest merged heaterbox systems (with single Quiet Pack) and love it - perfect fit and works really well.

JP

[jgerock]

Looks great - what are the specs on the engine?

JP

Thanks John - from my memory...
CB "Panzerwagen" AS 21 Brazil case (single relief version for some reason)
GB 1.5 Qt.  oil sump
GB "cow" magnet
GB full flow oil filter kit with steel pump cover and braided lines
GB 25mm (I think) oil pump
GB 69mm CW crank (std. bearing size)
GB 10.5 lb. flywheel (balanced to crank)
GB 104 dual friction clutch disc
KEP 1700 lb. pressure plate
GB Achiever front pulley
GB 90.5mm thick-wall pistons (92mm O.D.), balanced
GB 297 cam (same as Engle 110)
GB lifters
GB pushrods (cut to lenth)
GB solid rocker shafts with stock rockers
GB swivel feet adjusters
GB 311 shot-peened VW rods (balanced)
CB-044 CNC round port heads (40x35.5mm valves), 60cc chamber volume
CB  "Big-beef" port-match intake manifolds
Calculated C/R: 7.7:1 with Berg steel spacers (.040" deck height)
Dellorto 40mm carbs with update kit and GB 454 linkage
GB welded cooling fan
Bosch reman. alternator
"009" distributor, stock points/condensor and Blue coil
Stock VW thermostat, shutter flaps and all sheet metal in-place

Stock 4.12:1 transmission has Berg HD mounts and cross shaft
GB Engine support bar (cushion mount @ case)

[jgerock]

Engine should be ready to start tomorrow.  Today, I finished the wiring, fresh air ducts, air cleaners and R&R'd the Berg sump for re-sealing (not sure if that was an issue).  The older type sump doesn't have the cut-outs for the long cap nuts.  Major PITA to remove, scrape the old gasketing and re-install onto the engine.  I learned today that the best wrench size to use on them is 7/16" and not 11mm.

I even connected the heater flaps to the lever.  This car hasn't had heat for a long time.

[jgerock]

I got the engine running at 2pm today.  Filled the crankcase with Castrol 20W-50 oil along with some Rislone Engine oil supplement (with ZDDP) and a fresh oil filter


Made sure the battery was connected (was on the Battery Tender since November) and cranked the engine without the coil wire connected for oil pressure.  Turned on fuel pump and pressed the pedal down about 4 times then cranked it again - started right up!

Initial timing set and carbs synchronized quickly (Uni-Syn for now), then I went for a quick spin about 3 miles, stopping to check for leaks and making sure the thermostat extended all the way to open the flaps.  

The car feels like it has more power and now has a more interesting intake sound than before.  Will do some more tuning then take it out for some fresh fuel.

I am really happy after performing these upgrades.  I even swept the garage and washed the car before putting it away for the night.

[jgerock]

Two ads currently in place

http://www.thesamba.com/vw/classifieds/detail.php?id=1165341

http://washingtondc.craigslist.org/nva/cto/2498166811.html

Included in the sale are all my receipts (since 1993), instructions (mainly Berg), '71 owners manual, VW accessories booklet and Dellorto tuning book.

I also will be selling some parts I've accumulated over the years.  Anyone in the area is welcome to stop by.  I'm in Alexandria, VA just off the 495 Beltway (15 minutes to Reagan/National Airport and 45 minutes from Baltimore (BWI) airport).

[John P]

Congrats - very clean. It has got to be hard to sell it.

[jgerock]

Congrats - very clean. It has got to be hard to sell it.

Thanks John - it's been a long road since April 1993

[Dougy Dee]

Did you do any cam break in?

[jgerock]

Did you do any cam break in?

I did back in 2004 when the engine was built. I tried to follow the Berg instructions.  The fumes coming off the original Jet-Hot coated header set off the smoke alarm in my parent's garage - even with a box fan blowing!  The recent updates to the engine were just the heads, intake manifolds, exhaust system and oil cooler.

[jgerock]

I re-read the Berg instructions this morning for breaking in the engine.  

I recall doing the following back in 2004:

Left the oil filter bracket (no filter yet) hang down by the hoses while the crank case was filled with oil.  I used non-detergent 20 weight oil (ND20).
Remove rocker arms and pushrods.  Re-install valve covers.
Remove spark plugs and coil wire
Crank engine until oil comes out the oil filter adaptor.
Fill oil filter with oil (the Fram HP1 will hold about 3/4 quart) and install on adaptor - bolt to fenderwell.
Crank engine until oil pressure light goes out.
Dip pushrod tips in STP engine treatment and install
Install rocker arms, adjust clearance and pour some STP/oil on them before the covers went back on.
Install spark plugs
Turn key on to energize fuel pump and fill float bowls with fuel.
Re-install coil wire.
Press throttle about 3 times to squirt some gas into intakes.
Turn key and fire it up!
Bring rpm's up to 2000-2500 for about 5 minutes (this is the hard part).
Let idle, shut off, cool down.
Re-check valve adjustment.
Drive gently for about 100 miles, varying the load on the engine (no lugging or high revs.)
Change oil.  I went to conventional 10W-40 at that point.




I was so nervous about starting the engine for the first time, I tried to make sure I was doing it right.

[jgerock]

Here is a picture I took at the BugOut September 2009 show (Manassas, VA).  This was the first time I've shown it at the BugOuts. 

I didn't win anything (I wasn't expecting to).
Here is my judge's score sheet


I did enter and win two trophies in some local street rod shows a couple years ago.