Wednesday, May 29, 2013

It runs even better

Got the new VW carburettor in the post this morning. Less than 2 days to come down from QLD.

This afternoon Dad and I fitted the new carb on the engine, reset the timing, fired it up and fine tuned the idle. It runs so well now, no flat spots. We also changed the oil  after some running to flush out the system after sitting for so long.

Next job is to re-adjust the tappets and confirm the timing. Then it can go back in the frame. Just not this weekend. We will be working to get Dads M19 Fairmont back together. It went in for a mechanical overhaul 7 years ago and only now ready to be re-assembled.

The M19 delivered in 2005

I bought the M19 for a Fathers day present in 2005.

Saturday, May 25, 2013

It runs!

Yes the engine runs...sort of. As suspected the original carburettor is not ideal for the job. It's the industrial engine version where you just set and forget the throttle. The problem we are having is flat spotting. So we are going to fit the automotive type carb.

I picked up a brand new carb off eBay, should be here in a week.

Had a little trouble fitting the clutch housing back on, at some point something has changed, either different clutch plate or different release bearing but when all assembled the release bearing was jammed up tight between the bearing carrier and clutch plate, making the clutch slip. Some one had a go at rectifying it by putting spacing washers between the engine case and clutch housing but it still didn't allow enough clearance. The bearing carrier is a separately machined part of the clutch housing so some 6mm spacers were made to space the carrier further out. The release bearing now has room to move. If this modification wasn't done, as the clutch wears it would have started to slip and compound the problem.

The clutch housing holds the starter so it was fitted so the engine can be started on the bench.

All new hanger pins for the suspension have been made. These are 1/2" rod and new threads cut into them. The brake linkages were welded up, ground flat and re drilled, threads were cleaned up as well.

The hard wood blocks that the engine is mounted to were made to replace the rotten ones.

The frame is all painted and moved back into the shed awaiting reassembly. Oddly the engine will be the first thing to go back in then the axles and gearbox.

Engine mounting blocks

Engine all together

Frame Painted

New suspension bolts

Re-made brake linkages

The new bolts that are going into the VW

Wednesday, May 1, 2013

Down and dirty

Several days with angle grinder and bench grinder, both fitted with a wire wheel and most of everything that will be reused is all clean. The shed looks like a disaster zone with dust and paint flakes everywhere.

The frame was also flipped up the right way and painted. Left it to dry for a few days, now it's wrapped in plastic to mask off the hand rails. These are going to be black along with the foot steps.

The engine tins got a lick of paint and now ready to be assembled on the engine this weekend. By the end the engine should be finished and be put aside until it's ready to be placed back in the frame.

A great debate arose whether the axle boxes should be painted or left in their natural steel look. in the end they were painted. I have a seen other jobs were they have not been painted and while it does give a more machine appearance it sort of looked only half finished. A lot of work has gone into the VW to make it look special and it is being done up not just mechanically but it will be a show piece.

Next week it is back to work with my day job. It's hoped to get the painting done before them. So far it's looking good. Phase 3 of this project will commence, in the form of late nights assembling the whole thing. No where near the home stretch just yet but over the last two weeks it is progressed in leaps and bounds.

Engine tin ware

Some of the cleaned components

Brake rods

Axle boxes

Hubs, Sweeps, stays, many cleaned parts

Painted frame

Frame masked for painting the hand rails and foot steps
Dad on the wire wheel