On the last 10 miles back from Carlisle my tub developed a metal to metal annoying noise upon accelerating and putting a load on the engine-in the driveway it sounds normal even when I rev it up.The engine is a mexicrate that we built up to 1914 almost 5 years ago and now has 16,000 miles on it. It is a nonstrocker with stock heads and a mild cam (engle 100 or 110), dual weber idf 40s,electronic ignition, 4 quart sump, kennedy 1700 clutch and extractor exhaust with a phat boy muffler. I also installed a crankcase breather system that vents thru the valve covers to a box on the firewall. .I didn't think the noise was coming from the engine but I did the following: 1. checked the valves (cold) -all the clearances were at .006 and nothing appeared loose or bent. 2. took the fan belt off and checked the fan and alternator for looseness or end play-both OK and nothing stuck in the fan. 3.I took off the muffler to check for a loose baffle-nothing there. No leaks or looseness in the exhaust system .4. I checked all the tin to see if any was loose-all tight.5. I even changed the fuel pump and push rod to make sure that wasn't causing the noise. I was pushing the speed because we made the 200miles back from Carlisle in just over 3 hours.
I then called Kirk at Vintage. They built the car in 2006. He thought that there might be a broken or loose trans. mount.
Out of frustration I drove the car yesterday morning to Freccia Brothers Shop in Greenwich ,Conn-an old and well respected aircooled vw shop so they could put it on a lift. They called me today and so far can't find the source of the noise. Trans. mounts are OK. They drove the car and thought it lacked power so they pulled the plugs which I had changed about 1000 miles ago-one was fine,one was oily and two looked like there wasn't much combustion. They did a compression test -3 cylinders were normal at 135-150#but #2 read 250# ! All three mechanics have never seen this before. I asked if it could be excessive carbon buildup on the piston head or the valves-they said maybe or a loose head stud or a crack. So far they don't want to pull the engine and are looking for solutions. These guys have experience, and know their stuff. They gave ma a lot of time today on the phone.
Does anyone have any ideas?
Thanks,Joel