Engine block mods for better cooling and lubrication

Good that you tried it ... 

I would never have waited to find out how thin the wall was that you were drilling through.

I would have just gone as far as possible right up front - Why waste time?

But that's me.  You might have been more prudent (at least I hope so....)

The idea, Gordon, was to see if we could perform this mod successfully first. As I said, it was only afterward (we'd taken the time to open beers) that Gerry got that mischevious look in his eyes. I wasn't surprised, though; I've done enough 4 wheeling and off roading with the guy to know. Any time we'd come across a mud or water hole and someone new in the group would ask "how deep is it?", Gerry's standard reply was "you'll make that", and the fun would begin...

Thanks, Al. I was just talking about this mod for the Spyder build. I'm leaning toward having someone else build the motor but...

edsnova posted:

Thanks, Al. I was just talking about this mod for the Spyder build. I'm leaning toward having someone else build the motor but...

Engine builders will tell you it's not needed, and since the engine will run without, technically they are right. What you do get with the modifications, though, is an updated oiling system with less wear on lifter bores and rockers, and cooler running heads. With the engine running within proper temperature parameters a greater percentage of the time (it not being as affected by ambient conditions as much), the tune will stay optimal longer and it will make all the hp it's supposed to more of the time.

Have you thought about building it yourself?

I can't imagine doing this on a brand new mag case.  The stress would kill me.

The next case I drill will be new, and now that I've done it once it's not really that big a deal.

ALB posted:

edsnova posted:

Thanks, Al. I was just talking about this mod for the Spyder build. I'm leaning toward having someone else build the motor but...

Engine builders will tell you it's not needed, and since the engine will run without, technically they are right. What you do get with the modifications, though, is an updated oiling system with less wear on lifter bores and rockers, and cooler running heads. With the engine running within proper temperature parameters a greater percentage of the time (it not being as affected by ambient conditions as much), the tune will stay optimal longer and it will make all the hp it's supposed to more of the time.

Have you thought about building it yourself?

Yes. Considering the CB Performance 2110 Builder's Choice. Which I think (hope?) is not at all like "building it yourself" but might be OK for a duffer like meself. 

Anyone here have any experience with those kits?

Ed - Talk to Dale about German Motors/Wayne Ditmann in Stafford, VA.  He built both Dale's motors.  On the large one, he let Dale help so Dale could learn. Dale has had NO Issues with either and not even an oil leak.

"I can't imagine doing this on a brand new mag case.  The stress would kill me."

That's almost how I felt when I drilled and tapped my engine for a full flow return - the engine was fully assembled and still in the car.  It's a great leap of faith to believe the Berg Tech Notes on how to do it, but it works.

There is stuff here that is a lot like what one runs into when you own a home and stuff happens.  It's always the first ever time to do whatever it is that needs doing, and maybe its common sense or maybe there is a trick to it, and you don't know what until you've actually done it.  In hindsight, the job then becomes easy.  "drilling the case is the one everybody's afraid of. And you know, it wasn't that hard."  "The next case I drill will be new, and now that I've done it once it's not really that big a deal."  Lesson to all:  You will have to do it twice, so go buy a crappy case and practice, then get the shiny new mag case and jump all over it.

And the corollary to the house (or car) jobs that are almost always OJT adventures, just as often you end up doing it only the one time.  He may never have to go there again, but even if he does, Lane will never, ever have that same brass thingie go flying off into the ether, 'cause now he knows . . .

And now you ALL know.  But beware, there is more than one kind of "brass thingie" lurking in these cars.

El Frazoo posted:

There is stuff here that is a lot like what one runs into when you own a home and stuff happens.  It's always the first ever time to do whatever it is that needs doing, and maybe its common sense or maybe there is a trick to it, and you don't know what until you've actually done it.  In hindsight, the job then becomes easy.  "drilling the case is the one everybody's afraid of. And you know, it wasn't that hard."  "The next case I drill will be new, and now that I've done it once it's not really that big a deal."  Lesson to all:  You will have to do it twice, so go buy a crappy case and practice, then get the shiny new mag case and jump all over it.

And the corollary to the house (or car) jobs that are almost always OJT adventures, just as often you end up doing it only the one time.  He may never have to go there again, but even if he does, Lane will never, ever have that same brass thingie go flying off into the ether, 'cause now he knows . . .

You are absolutely right, Kelly; any job the first time can be a little unnerving, and doing it the first time on a junk case takes off the pressure, and you learn so much at the same time. I'd also read along the way of 3 or 4 people breaking through that area, and in all instances the guys were at a loss to explain what went wrong. It looks to me to be either differences in the case castings or the factory machining are causing the problems. Given the thin amount of material that we found separating the new passageway and the outside of the case, that's why I've suggested filling the bottom of the depression with epoxy before starting is the way to go, as I think it's obvious VW never intended to drill that area.

With a junk case to practice on you could also do the full flow modifications, drill and tap all the oil passages for plugs after cleaning (so you know the inside of the case is truly clean after your brushes have been everywhere), and if you save the magnesium chips they make great fire starter when sprinkled on tinder for camping. Small chunks of the case are fun to throw in the fire too, or so I'm told. Not that I've ever done that.... 

saw a cool "science" clip on FB or youtube the other day, guy playing w Mg in the backyard.  Kinda cool.  Even showed the Mg chips thing to start a fire.  Lots of smoke and fire, but nothing until he showed how not to put it out, i.e., with water.  Class, can you say: conflagration??

If you put 10 or 12 toilet roll centers (the cardboard part) inside each other, cut it in half (so you have 2 short pieces) and dip 1 end in wax they make great fire starters. sometimes offroading we get caught in the rain so they're really handy. Next batch I make I'm going to sprinkle some magnesium dust on before the wax sets (or maybe jus mix it into the hot wax....hmmm, that may not be such a great idea- a fire in a pot that's really hard to put out; mind you, it takes a lot of heat to melt magnesium, and I don't think wax gets that hot).

Anyway, Kelly, if you hear on the news about some idiot on the west coast burning down the townhouse complex with wax in a pot on the stove, you'll know what really happened....not feeling very Yoda-ish (or wise) at the moment Al

Right.  Lane, pls see recent bump-post on my alternator problem.  again, the "I never did this before" angst has worked on me big time.  And, you were right last fall about how to get the alt and fan combo out -- one just loosens the shroud (two bolts, one each side) and there is enough wiggle to allow it to come out.  I should not have fretted so much about that.  Now, getting the fan off the shaft with the thing sitting in your lap, well, that is whole other can of worms . . .

When you do this on a new case, Al, I'd really like you to take pictures of every step along the way.

Stan Galat, '05 IM, 2276, Nowhere, USA posted:

When you do this on a new case, Al, I'd really like you to take pictures of every step along the way.

Me too.

"If you put 10 or 12 toilet roll centers (the cardboard part) inside each other, cut it in half (so you have 2 short pieces) and dip 1 end in wax they make great fire starters. sometimes offroading we get caught in the rain so they're really handy. Next batch I make I'm going to sprinkle some magnesium dust on before the wax sets (or maybe jus mix it into the hot wax....hmmm, that may not be such a great idea- a fire in a pot that's really hard to put out; mind you, it takes a lot of heat to melt magnesium, and I don't think wax gets that hot)."

I am SO GLAD that I didn't hang out with you guys when I was a kid.  What I did was bad enough.  I'm amazed you are still with us (and I bet YOU are, too!)

Gordon Nichols posted:

I am SO GLAD that I didn't hang out with you guys when I was a kid.  What I did was bad enough.  I'm amazed you are still with us (and I bet YOU are, too!)

We weren't allowed to use power tools (power saws, primarily) until we were 5. I thought it unjust.

True story.

 When I was, I guess, 17 years old, my friend, Ron, and I, with the help of a few friends built this July 4'th cannon.  Initially we fed it with Propane but quickly found that Oxy-Acetylene produced a MUCH bigger "Boom!" And could shoot a half-filled Coke can about 1/2 mile.  Fired it off about a dozen times that holiday, but on one of the last times when we fired it (a particularly robust "BOOM!) it blew out my ears so that, for the next week or so, all I could hear was ringing.  Awesome, friggin, cannon, though. 

Decades pass.  I have kids.  My hearing marginally improved.   My daughter grows to womanhood and gets married.  I meet my daughter's father-in-law's brother in law.  We talk about his hobby of Black powder musket target practice at the Leicester Rod and Gun club (Leicester, MA).  He tells me the R&G club has this awesome cannon that he got from "his friend Ronnie".  Sonnofabitch.....It's the same ear-popping cannon.  

Maybe you guys shouldn't hang out with me, either.........

I've often wondered that myself, Gordon.  

@Gordon Nichols, your post reminds me of these: http://www.toycannons.ray-vin....carbide/howworks.htm 

Yeah, only we took the easy way out and fed ours with an oxy-acetylene torch with the flame popped out.

It is truly amazing that, with all of the nutty (and dangerous) stuff that I've done to this body in this life, I am still around - and telling about it.  Must be really good Ju-Ju.......

Or.......The Angels are using me as an example ("See THAT?  DON'T DO THAT!")

Gordon, you have no idea, man.