Out of the Closet

[killerken53]

https://aapistons.com/products/96mm-...ged-piston-kit

These anywhere close?

[Steve Demeter]

Way back long ago Bertil built an ACSV engine for Phil Rosette for the 1980 runoffs. Since 1600 cc was still the rule and 1600 jugs were not to be found, Bertil sleeved a 1700 set. That motor had amazing HP, but mainly because the heads were so good. So if Jugs are impossible to find you could conceivable sleeve the bad one.

[BURKY]

This engine has to come out under the car. Sort of a PIA. But, as Kummer always says. "If it were easy everybody would be doing it.
Two hours later...

These guys make it look easy...
http://imgur.com/gallery/Jp9Jl6D

[Purple Frog]

I have had a lot of communication with Jake Raby about the engine, especially since he built it.
At first he thought i was just some wanker, but after showing him the project and my resume, he kindly started answering a lot of questions. I am thankful for that.
Jake has progressed in his business career to a point where he is building very high end powerplants for the P crowd.
Not unusual for a engine from him to come in over $30K. His minimum to even attempt a refresh of my engine would be $10K. Those that have followed me on Apexspeed for 18 years would know that is too rich for my blood.
His expertise has advanced a lot since 2003 to the point that most of my engine would be throw-away pieces when compared to the level of parts he uses today. I totally understand his position. I'm just glad he filled in some of the blanks.

I have also discovered the head builder is still in business, and has the records for my heads.

I have to laugh about the popsicle stick ring groove tool. One of the ring grooves is only 1.2mm. But we haven't given up on trying to save the two pistons. It looks like JE might have the correct rings in stock.

I am going to check out the FAT catalog.

It would have been a lot harder to remove the engine if I had not of bought the $600 floorjack from Pelican that has a long reach and 32" lift.

Onwards and upwards.

[DaveW]

...But we haven't given up on trying to save the two pistons. It looks like JE might have the correct rings in stock.....

Have you tried heat and/or dry ice on the pistons to heat/shrink (aluminum vs steel coefficient of expansion) and cause the rings to loosen?

[Stan Clayton]

I have to laugh about the popsicle stick ring groove tool. One of the ring grooves is only 1.2mm. But we haven't given up on trying to save the two pistons. It looks like JE might have the correct rings in stock.

That was me.

1.2mm is 0.0472". I just measured a popsicle stick at about 0.057", so yeah, they won't fit. Use some shim stock with emery paper instead.

[Dave Welsh]

In the interim, while you are working on the Raby engine, here is something you might try.

Go to 1:29 in the video.

https://www.youtube.com/watch?v=-BE476MvO_g

It keeps with the air cooled theme.

[Steve Demeter]

Had a dumb (probably ) thought. Can the heads be pulled without removing the engine. Used to change rings and occasionally rod bearings with the engine in the ACSV car. Just a wild thought.

[Purple Frog]

First the holidays. Then a two week trip to Vermont.
But...
Engine is out. (Decided it would be way too difficult to do repair in the car.)
Analysis complete.
All dis-assembled.
All the pieces and parts needed for the rebuild are in the shop.
Now I need to start cleaning everything.
Lap the valves.
Hone cylinders.
Fit and install the rings.
Put it all together.

[DaveW]

Great!

So I have to assume you were able to get the 2 sets of stuck rings off and save the pistons? What finally got the rings loose?

[Stan Clayton]

What finally got the rings loose?

WD-40 and a soft hammer. (Way too many years behind a Detroit Diesel 8V71... ;^)

[GT1Vette]

First the holidays. Then a two week trip to Vermont.
But...
Engine is out. (Decided it would be way too difficult to do repair in the car.)
Analysis complete.
All dis-assembled.
All the pieces and parts needed for the rebuild are in the shop.
Now I need to start cleaning everything.
Lap the valves.
Hone cylinders.
Fit and install the rings.
Put it all together.

One more item for the list:

. Remember to launch the beast in second gear going forward!

[Steve Demeter]

Actually if you can get a 5 gallon pail of Gunk Hydroseal it will probably get the carbon in the ring grooves to dissolve. Always used it for AC heads and pistons. After a couple of days soaking the carbon came off with a toothbrush.

[Purple Frog]

The beast runs again!
It's been hard to find time to work on it, what with holidays, ski trips, and lots of Hurricane Michael rebuilding projects.
With the help of the interweb and FedX we found all the needed parts.
Only cleaned the old pistons, installed new rings, and honed the cylinders.
Just lapped the valves. Thanks to DaveW and his old valve spring compressor.
Cleaned everything up and reassembled.
Poured in Joe Gibbs break-in oil and a can of BG's MOA.
Cranked it to get oil pressure, flipped the ignition switch on, and it just started idling.
There is joy in the swamp tonight.

[killerken53]

Great news! Now go and enjoy the fruits of your hard work. As you are well aware the ACVW is not a car, it is an addiction.

[TimH]

Second gear!

[Purple Frog]

Not only does the beast run in the shop....
I just drove it 3 miles around the neighborhood.
Something Eric started like 14 years ago is now a reality.
Sort of exiting. You know if you ever built something from the ground up.

And it hauls the freight.
But.... I think i've been launching in 4th gear to be safe.

Trying to get a video on Youtube...

[Purple Frog]

I decided for local events I needed a trailer that was easy to load.
No reason to use the enclosed trailer for short trips on nice days.
I saw nothing on the market that was affordable.
Looking at the Interweb I saw that in Europe where gas prices are high and they tow with small sedans... they build light weight open trailers.
So.. I built one this weekend.
I had a goal of $1,200.
I'm in $1,400 with LED lights, paint, spare tire, etc.
I could have probably saved some if I shopped more careful.
Ready for paint.

4" drop axle
It is a 15' tilt bed. No pesky ramps to fool with.
Electric brakes.
Took 2 and a half days of puttering around with the MIG.
Plan to add a front windscreen.

[mmi16]

I decided for local events I needed a trailer that was easy to load.
No reason to use the enclosed trailer for short trips on nice days.
I saw nothing on the market that was affordable.
Looking at the Interweb I saw that in Europe where gas prices are high and they tow with small sedans... they build light weight open trailers.
So.. I built one this weekend.
I had a goal of $1,200.
I'm in $1,400 with LED lights, paint, spare tire, etc.
I could have probably saved some if I shopped more careful.
Ready for paint.

4" drop axle
It is a 15' tilt bed. No pesky ramps to fool with.
Electric brakes.
Took 2 and a half days of puttering around with the MIG.
Plan to add a front windscreen.

Some front wheel stops won't hurt. Saw a guy at Roebling Road several years ago, T1 Corvette - drove it over the front end of his trailer loading it.......

[Purple Frog]

Paint on.
Rand decided the color.
Stops added.
Also added a winch just in case i blow the engine again.
Loads and unloads like a dream.

[ChristopherBernard]

Purdy!
Lotta frogs!
Love Lightweight!

[john f]

Drive it, don't trailer it. It's a hot rod.

john f

[Purple Frog]

i do drive it. But, it is not licensed for the street (yet).
I have a secret little three mile test course.
Working on an appraisal for Hagerty. Then, maybe i could afford insurance.
(way too many vehicles and license plates already.)

Even though all the lights, horns, signals, etc. work... it requires 112 octane race fuel and is sitting on 4,800 pounds of springs with less than 3" of ground clearance. Totally hates speed bumps. So if i put it on the street, it will be for special occasions.
I doubt it would be much fun in stop and go traffic.
For now its a track day car.

[Purple Frog]

So... took a day off and mounted a video camera in the bug.Took it for an easy drive around a 3 mile loop in the neighborhood. Lots of turns and LOTS of elevation changes.
Still clumsy with footwork in that tight foot well.
A little rusty driving a stick shift car again.
Have not driven the "ring" in about a year, so a few times I was a bit wondering where it went.
I basically drove it in 3rd and 4th gear. Kept the noise down and the neighbors happy.
The engine has so much torque it is easy to drive slow in 4th.

And, on my PC the video looks great... on youtube it is grainy. I guess i have a bit to learn about video production.


Anyway... Tim Minor keeps saying... "show me a video"
DaveW will recognize the course.


Here goes. Long and not edited.




https://youtu.be/qrfNBt00mI0

[Ralph Z.]

Sweet!!!

[TimH]

I kept imagining that motor at full song ... SCARY!

[Purple Frog]

I'm running a muffler. Even so, Inside at 6500 it is a trip.
I'm so tempted to put the straight stinger pipe on...

[TimH]

Actually, I was thinking more about how quickly the scenery would be rushing up at you.

[Purple Frog]

Actually, I'm sitting so low that it is a bit of an effort to see out over the dash. Might need some phone books on the seat. Eye level is about an inch above the bottom of the windows.
So used to driving a truck every day, sitting down on the road is different. The camera is mounted about 6" higher than my eyes.
Gotta keep that low C/G and all.

[EricP]

Even more now, I hope you bring it to the Put-In-Bay races. They are even doing a VW specific race this year!
http://www.pibroadrace.com/

[carnut169]

Great weekend at the ARRC- except for FB turnout...1 car where I was able to see some old friends (Russ McBride, Cooper, Court, Eakin, Marshall Aiken, Fletcher and a lot more) and watch a huge FC field plus an even larger FF field take the green. Some close racing that was fun to watch and also depressing- I was watching, not driving.

However that's not the reason for this post... I DID get to drive a race car this weekend. A car that sounded, accelerated and felt a lot like my old Pinto Powered FC in the paddock. From the very tight footbox to the exposed tube frame- the racing harness, ignition switch and start button all reminded me of that old FC.
I could feel that above 4k rpms this thing would be a lot to handle- knowing my dear friend invested a lot of precious time into completing this build I was taking no chances- especially since I was the only person he's trusted to pilot this beast. I slowly drove from the camping area near turn 5 to the skid pad between 6 & 7. From Inside the car the built Porsche flat 4 was screaming- even at 3500rpms. The smell of race gas and my feet on top of each other gave me flashbacks. I entered the skidpad and desperately wanted to jab that go pedal, send the Beetle sideways and put on a show for the 5 or 6 onlookers but wanted to bring it back in one piece a bit more so she took a more conservative line. Still, crazy fun.

Mike has a very unique toy in this "beetle". Its really a formula car disguised as a Beetle... the power to weigh ratio is off the charts and the suspension is rock hard. He needs to get the thing on the track where it could really be appreciated- assuming the body stays on!

Impressive in every way (you have to check out the fake fuel tank) this is a really cool build. Way to go Mike! Enjoy the videos and turn that sound up!


https://youtu.be/naSu2Vka4QE

https://youtu.be/drLy5g8V_as

[t walgamuth]

What a fantastic build!

[Rick Kirchner]

Gen II?

[TimH]

No. Just... No.

[Purple Frog]

Actually I like the Gen II version... probably with a bit smaller front tires, and smaller scoops. Of course since Gen I is street licensed, got to add lights and such...

Meanwhile.... there have been a few updates to the Outlaw Bug since the 2019 post. Fun Sunday driver.

[GT1Vette]

You're right, it looks MUCH better with the silver wheels!

[alangbaker]

...with something to shoot for:

[Purple Frog]

Very good build Nice job! Great street cruiser!

But not mid-engine, not tube frame stiff, not racing suspension, not 1350 lbs.

Langbein driving the "Outlaw Bug" would tear him a new one in 10 laps at Summit Point.

O.K. I admit, the Captain and I are a bit testy this evening. Ignore everything typed above... except for the honest compliments.

OBTW, thinking about a new set of Toyo R1Rs for the bug. I'm getting more comfy at 7,000 rpm... but the alternator belt is not.