Projekt Hoopty update -- 20 Oct. (photos)

There are two more shots of the fan shroud and generator but ther're really not accurate as 'final assembly' pictures. I have to wait on putting the generator in until after the engine, motor plate and transmission are bolted in, just because of the way they go together. That's the third picture, and there will have to be more aluminum sheet put in on either side of the plate itself to seal the compartment. (That happens after we run the car around the block Monday.)
I also took the oil cooler segment of the DTM off because I wanted it shiny black like the block. It, and its hoses, are not installed yet, nor are the generator pulley, dipstick, temperature gauge or plug bits. That happens today or tomorrow.
I'm really very happy with the overall level of detail work on the engine. If you have a close look at the underside photo, as well as the two where the case is in pieces, you'll see that the case was in fantastic shape to start with. Probably not many miles on any one part.
The Elder Wrench suggested going with black paint instead of leaving it aluminum because of the dissipation properties of black.
He's 'The Man' 'round here; I took his word for it.

Whaddy'all think?

I don't have much time to caption these right now, but I will put info in the image files later tonight.
The elderly man in the photos is the guy who wants to see the 911E mill installed.

TC, I couldn't keep back the Skunk Works pictures. I tried, but damn ...

Cory,

It just keeps getting better! You and your crew are doing some great things. Not wanting to contradict your crew, especially considering the exceptional work, but doesn't the heat of black vs. other colors have to do with light (photon) absorption/reflection and not actually heat transfer? Still, perhaps there is a reason that the painted dissipates better. Just a thought...(I like the looks of the paint).

Keep up the great work!

Thanks!
Hey, for Type IV folks -- I learned something new yesterday. The tins that surround the bottom of the cylinders are supposed to be held in with three screw-in fasteners. The usual shade-tree protocol is to use two, apparently, but failure to add the third can result in the tins flapping against the pushrod tubes. Eventually, the pushrod tubes will get worn through where the tins hit -- and it's likely to be the middle ones on each side because it's the center fastener that gets left out.
Huh. I don't have an example to share with the wear-marks on it, but I'd say it bears checking on y'all's engines. I'm using stainless Allen-headed screws for all six fasteners.
Jst thought I'd pass that on. My lower tins came from a microbus.

Robert, that was a great question -- so I researched it. Hindsight is 20/20, and I can now clearly see what I should have read before I painted!
My engine is fancy-fancy for inappropriate reasons. This article (link) is informative, discussing how most paint is the same in the infrared. The summary is painting is better than not painting, but black and white are the same to an engine for heat dissipation purposes. The rest of the story is that it DOES make a difference what color you paint your engine surrounds and compartment.
The principle involved is purported to be Kirchoff's Law:

http://www.sacskyranch.com/paint.htm

If I understand it correctly, the air passing my orange cylinders is not less likely to pick up radiant heat from them than from the top of the block. The fact that the cylinders are painted does (albeit insignificantly) increase the overall surface area of the cylinders themselves, and since the paint is bonded to the metal of the vanes ... through-put energy transfer happens at the same rate over a greater surface, making it a more efficient process of dissipation.
Except that the surface area of my four little jugs is not anywhere near the surface area of a thermoconducive hydroelectric plant, for example, which would see a measurable net benefit.
Ultimately, it will be the efficiency of the shroud and fan, configuration of engine compartment tins, the flow pattern, and the volume of heat exchanged at a predictable rate which keeps my engine running smoothly at a low operating temperature.

Hmmm. ...

So now I'm stuck with the Baltimore Orioles' scheme for no reason. Fooey!

Not for "no good reason" Cory. Because it's cool. That's all any of us needs to know. Doesn't hurt a thing and looks cool!

Real real quick you're going to have "fire in the hole" my friend.

angela

get that tub together it's almost Halloween, just kidding, lot's of work/detail being done at this point, it's 110% of pure dedication pull yourself together man wipe that smirk off your face we got work to do, focus man focus. Lt. Cabanaboy at ease

"TC, I couldn't keep back the Skunk Works pictures. I tried, but damn ... "

Well, crap! If YOU'RE not gonna keep any secrets, then I'M not either . . .

Unlike Cory, I decided to keep the my engine simple and go with the "stock" VW colors, black, gray, aluminum, off reddish brown and such. Stock brained cloth hoses and what not. Since the coupe is a mixture of Porsche and Speedster body parts with VW mechanicals, I kept to the VW heritage with the engine as well. Already had the adapter, just bought a new lightened/balanced flywheel and a race clutch and pressure plate.

Here are some pics of the nearly completed engine:

http://img.photobucket.com/albums/v136/TeamEvil/eng12.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng10.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng9.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng7.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng6.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng5.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng2.jpg
http://img.photobucket.com/albums/v136/TeamEvil/eng1.jpg

Sorry about the Photobucket thing, I don't know the step-by-step for posting the thumbnail.

Gotta REALLY get rolling on this if I'm gonna get it to Carlisle.

Well Cory; fire in the hole was what I shouted on Friday afternoon; we got my engine running and tuned up. The sound of the Tri-Mil system is great; throaty and very much like an old 356. The Gene Berg chromoly pushrods do make a sort of ticking sound and are noisier than aluminum pushrods.

Yesterday afternoon Jjr and I installed the engine in the car along with the new gas pressure regulator, adjusted the thermostat/shutter system and installed all the tins on the motor. We were finished around 7 or 8 pm and we fired it up and took it out for a drive. The dual Dells feel wonderful (and yes, they whistle but it doesn't bother me) and now it feels like a totally different car. It has more torque and a meaner sound. We still need to fine tune it just a little but it's there 95% and it feels great. When you get to road test your car you'll know what I mean; especially after all the blood sweat and tears that have gone into yours......

Ricardo -

Woohoo - nice engine work and I'm sure you guys had a blast running the car with its new engine on shakedown drive. Congrats!

As for the whistle, do you think it might be the baffle inserts on your muffler. I'm guessing it whistles on idle but not on rpms above idle!

Anyway, have fun with your new powerplant - let us know how it performs once you've broken it in and re-tuned!

Peace - Out!

Actually Jim; Dellortos whistle; it's the nature of the beast and they actually do when you're running, not at idle. There's some gaskets available to prevent the whistling but I don't mind; they make the car sound meaner. Turns out that this afternoon Jjr and I were going to visit an old friend who's working on kit cars since the '60's; Jjr came in his recently restored Manx clone dune buggy and I took out the Speedster. I didn't drive long before the car started missing and feeling like it was running on 3 cylinders. We returned to my home (not before Jjr had to go get his F-150 to tow my car). It hardly stays on at idle. We finally isolated the problem to cylinder #2. We removed the spark plug on that cylinder and strangely enough it looked pretty clean and didn't even smell of gas. We removed the jets for that cylinder and found them not to be clogged. Since it was late we just left it in my carport but we're suspecting either a very lean mixture on that cylinder or a screwed up spark plug (in this case a 12 mm Nippon Denso; tried to find Bosch of that size at first but couldn't even after searching CB Performance and a couple of other places). So this is where we stand and as you know, that's part of the fun so we'll report back after we finally get this thing dialed up and running like it should; hopefully soon!

TC - what engine is that? Looks like a pushrod V6, maybe a Ford? Very cool valve covers! angela

Thanks Angela!

It's a 4.1 liter V6, out of a Caddy. Same motor that was offered in the Buick Rivieras. I like the GM V6's for the reduced weight and the 90 degree configuration. The adapter kit from KEP for the 3.8 works perfectly. The timing cover from the first year even-fire Buick and a short water pump from a non-AC car and everything seems to fit pretty well. Of course, there's STILL some cutting involved for the distributor, and the deck lid runs with stand-offs, but . . .

Hey Ricardo -

I didn't know that about Dellorto's. In fact, a friend recently dropped by in his Karman Ghia, and coincidently is runnning a set-up very similar to yours, very cool. He also, pointed out the sound those carbs make. I learn something new everyday (mostly from this website).

Good luck with shaking out the bugs (no pun intended) on your new engine - the satisfaction from getting everything dialed-in to make that engine purr will only add to your SEG!

Peace - Out!

Thanks bro! Sometimes it's kind of a drag but it's also part of the fun.....I also read today that if any anti-seize compound gets to the electrode it'll short out the plug. I put anti-seize on all the spark plug threads, maybe that one shorted out?

Okay, TC. I'm sure you've been wanting to let the cat out of the bag for a while. Feels better, doesn't it?
Wow.
Ricardo -- cool beans! Glad to see it's coming along and working out for you!
We're in the home stretch now. Details later. ...

Update; got it all sorted out today. The problem was that the right carb wasn't getting any fuel...no wonder the thing didn't have any power (it was running on two cylinders!!!). Ralph removed the fuel pressure regulator from the loop and now it's as good as new. Thankfully the spark plug on cylinder #1 didn't suffer and I'm glad since I paid $4.95 for each of those Denso plugs....

Ricardo, mi amigo!

Get your motor running - Head out for the Highway - looking for adventure - and whatever comes my way (Steppenwolfe)!

Peace - Out!

That's a great song Jimbo! I used to play it all the time in bars around here.....people seem to like it a lot especially the yuppie biker wannabees.....

You're right, Ricardo. I would venture to say that 80% of the Harley owners in my area are CPA's, Dentists, or Realtors! That's a tough crowd I wouldn't want to mess with!LOL!!

(unless I chipped a tooth while reviewing my tax returns with my mortgage broker!)

Just wanted to post this picture of the engine already installed in the car.

Looks wonderful, I LOVE that oil filler ! ! !

I drove the Hoopty last night. There will be photos up sometime today or tomorrow.
Minor, minor work left to do. ... More as time/energy permit.

I remember the problems with rust that you encountered when your ride was outside and just under the tarp.

Last month I stripped all of the paint off of my daily driver, going for the "Hood Ride" look . . .

http://img.photobucket.com/albums/v136/TeamEvil/DSCN0190.jpg
http://img.photobucket.com/albums/v136/TeamEvil/DSCN0189.jpg
http://img.photobucket.com/albums/v136/TeamEvil/DSCN0187.jpg
http://img.photobucket.com/albums/v136/TeamEvil/DSCN0186.jpg
http://img.photobucket.com/albums/v136/TeamEvil/DSCN0184.jpg

Not Speedster related, but kinda worth a look. Those suitcases on the roof come in real handy when I need to carry a change of socks . . .

Wow TC! The bug headlights, tailights and license plate light don't look that out of place. Regarding the oil filler; it's a Gene Berg oil filler/breather and the design is almost a direct knock-off of the old 356/912 filler/breathers.

(Ahem ...)
May I introduce ...

http://i105.photobucket.com/albums/m231/paininthebug/DSCN9722.jpg
http://i105.photobucket.com/albums/m231/paininthebug/DSCN9717.jpg
http://i105.photobucket.com/albums/m231/paininthebug/DSCN9712.jpg

... Yup. That's a burnout on the floor of the garage.
Total distance; 15 feet. Then the test of reverse and that's where she sits.
But dammit, it WORKS!

More photos later in the more conventional form. Best I can do for now.

Man, I know you're tickled to get it moving on its own. Probably as close as you'll come to giving birth!
ed

*************ITS ALIVE!!!*****************

Nice job Cory! First move is a burnout - NICE! But there's something missing. Hmmm. What is it? Oh yeah, I know. A picture of you with a SEG driving the little monster!

angela

I spoke to Gordon last night and he said that you were pretty sure about a trip down this way in the next few weeks. 'zat true? If so, WOOHOO!!! With my luck, though, I'll be out of town on business.

SEG photo to follow. The Wrench drove it last night, and he wants to shorten the shift rod by about half an inch, make the engine compartment tins (and Lexan), and we have to wire lights to the four corners from their disconnection points.
We also have to finish-weld and paint the header and put the rest of the lug nutz on, so I may not be able to road-trip it until late Saturday. For now, though, I'm tickled to death!

Good deal Cory! Looks bitchin'!!!