Getting the syncro back on the road

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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

Posted this in the Wasserboxer forum but it all ertains to this so will add it here as well as the ultimate answer

The heads I just had built have much longer valve guides than either my stock AMC or a Stock VW head and I am wondering if this will be a problem and believe it to be the cause of my sticking valve :evil:

Here is a picture of my freshly rebuilt AMC head with valve guide:
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Stock AMC head from a Boston Bob engine:
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Stock VW head for full comparison:
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Well in order to make sure I cover all bases in case you want more information I will give you the background of why I became concerned with the valve guide length. I put the engine together with a Canadian remanufactured bottom end that was left as is with less than about 30,000 miles on it but was putting a lot of combustion gas into the coolant. I re ringed a set of OE pistons and cylinders from another engine to replace the low compression pistons in this one. The head seem to be my stumbling point now, The heads are AMC castings that at least one has spent some time in a GEX engine and were passed over by Boston Bob for use as new AMC heads were cheaper and easier than having these rebuilt as the guides were waaaay out of spec. Well as I got the head in a trade 0 cost there so I purchased a full set of SI swirl polished valves and a set of their guides as I suspected the ones in the head before they went to the machine shop. I used a shop local to me who's head mechanic used to build race beetle engines, as I couldn’t find any one else I put my faith in them. The heads came back fine and looked good. They sat around for a year before the engine went together and ran. The engine ran great went to temp at least once and ran up and down the street fine I took it around my parents field as its not registered and while creeping back to the drive way it stalled. I was able to get the van started again and get it to its car port and had to head home for the week for work the next week I found one push rod dropped half out of its cup in the rocker arm and was bent but every thing else appeared fine. I replaced the push rod was extra careful re installing the pushrods thinking I might have not seated the one right when I built the engine, or the lifters that always seem to bleed down had given me a bad initial adjustment that caused the issue. So I put in a spare push rod and re adjusted all the valves fired it up and the van ran great. I took it for another jaunt down the street to feel it run and get some speed hit the end of the 3/4 mile of road and went to make the u turn and it dies, and would not restart. Got it home to find the same push rod had dropped. After further investigation I found it was worse than I thought.

Here is what I was greeted by when I removed the valve cover:
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Here is what I found when I compared the valve springs on that side:
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so after wallowing in the thought that I was going to need to pull the engine pull the heads and have them re done for too tight valves I picked up an abused Boston Bob engine to reseal and seal up the oil leaks and hoped to run that while I worked on this engine again and while I worked on that on weekends a member on TOS had a similar issue with the valves sticking on a Syncro he was resurrecting after sitting for much longer. He spoke to his machinist and his machinist said they found black deposits on valves of cars that had sat for a while and when he removed his intake he found exactly that so as mine had also sat for a wile while the engine was waiting for me to finish college and have time and money then get a job where I wanted to work on it so I figured what the heck might as well check and lo and behold there was black gunk that wasn’t there when the engine was being assembled so I emptied the tank and am going to put a set of rebuilt injectors in also. After removing the intake and trying to look at the valve I found some reaaaly long valve guides and thought it time to ask some who know much more than I aka all of you. Next to do on the Syncro is replace the fuel level sensor again (I think for the second time my father thinks for the third) and hopefully drive this SOB

Sorry for the long post I just want my van drivable andnot the laughable vehicle it currently is :x
Alex

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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

Well the last time I was running the engine some gas started leaking out of the fuel level sensor… well after poking it with a screw driver over the long weekend I ended up with the elbow in my hand :x well time for ANOTHER level sensor for this van as I alluded to in my last most I remember replacing it with my father once before on this van (he did the work I helped back in the mid nineties) he believes it may have been done on this van once before that (there was a Syncro prior to this one it could have been also) so I sprayed PB on the whole thing and let it sit for a week Sunday I worked on getting all the rusty bolts out well after some time with the wire wheel and some pressure they are all loose (will get pictures next weekend) I purchased a new sender and a in tank ring as the studs on mine are getting a wee bit rough. here is the new one not rusty :lol:

Image
Alex

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fusername
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Re: Getting the syncro back on the road

Post by fusername »

if you want to cut the guides, that is a thing you can do, caaaarefully. your post confused me quite hard, as i think some of that is copypasta, was having some serious dejavu. also I have a head guy who does all my VW stuff in waltham. he takes a while (does a lot of stuff worth a good touch more than our beastes) but has always been very good to me. I think i gave you his number once.

T-fest?
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

That’s the goal Fuser get the van running and have it ready to go for then either with the interior that’s in it or with any luck with a full weekender interior just got the right pieces for a van without AC :D

Top pair is for a van with no AC the bottom pair is for a van with AC
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Here is a shot with all the parts plus the AC panels but none of the seats
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As my van is an L it already has all the stuff for the jump seats and the rubber floor so the only major thing is riveting in the table support, the top aluminum rails and welding in the rear pins for the backseat the side panels are already modified for the three point seatbelt
Alex

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fusername
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Re: Getting the syncro back on the road

Post by fusername »

sounds like you sure know where you stand. I am pulling an all nighter tonight, if the cage is done tomorrow and I find a muffler shop i trust during the week, I hope tofier her up next weekend. everything will be in primer at t-fest, but what ya gonna do. I have a real, if part time, job now, so between that and school I have bigger priorities than the SWB. sure they may be the rail, but lets not get too fusy over the details.
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

well the Fuel level sensor is done notoneof the roomiest places on the van to work :roll: here is the wheel well for access the charcol canister tipically resides on the other side of the springpearch but was out of the way onthe other side and kept the hoses in order

Image

here is the actual hole in the tankwhere the levelsensor goes.

Image

in this shot you see the level sensor that was replaced about 15 years ago, the sensor I replaced and the new sensor, the old and new gasket as well as the old in tnksplit ring and half the new SS split ring

Image
Alex

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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

Well I have plates for the Vanagon :D once again so it is time to try and actually drive this thing and hope I can make it further than the end of the street :lol: so tomorrow I will try to put some miles on the van and get the engine broken in a bit. All was great until this morning when I started having nightmares about it one proceeded with my father driving the van before it got warmed up (my plan to help the engine reach final size and have a good thermal load on all the metal to help a possible valve guide shrinking theory I have), and he turned it off way too soon and most of the valves stuck he proceeded to tell me the engine did not seem to have much power and was not very good any way :x :( . I then had another dream where it was running good but came upon an intersection and had no brakes and just had to run through it :shock: and not get hit which if I remember correctly we did successfully but I think I am a bit nervous about driving it tomorrow :?
Alex

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Re: Getting the syncro back on the road

Post by fusername »

The good thing about these dreams is they get all the horribles failure out of the way so when you actually drive it you'll be fine.. t fest sounds likely for you! If we both make ir, want to caravan so we have backup?
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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ajdenette
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Re: Getting the syncro back on the road

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I'm not saying anything until after tomorrow :roll: I dont want to count my chickens before they hatch I will see if I can borrow the westy if tomorrow does not go well but would be happy to caravan with you to make sure we get there saely also :D
Alex

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ajdenette
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Re: Getting the syncro back on the road

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:D :D :D It drove very well today and had no major issues with it. drove it around, got gas, luckily I brought my father with me as we had to pop start it :roll: but as we had to use the jump pack to start it initially it made a lot of sense need to work on making it charge better. cleaned all the parts that had accumulated in it over time then went and delivered the plates from my wife's car to her parents as they will go on their new car. So it looks like I will get to take my own vanagon 8) :D to Transporter Fest next weekend :D
Alex

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Re: Getting the syncro back on the road

Post by fusername »

Congrats man! I have a charged spare battery if we need to throw it in the back just in case for Sunday. Just got home from Lou's ten minutes ago, he seems confident I will get it back before the week is out, then some engine breaks in and a few oil changes later operation Hatchling Caravan can commence!
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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ajdenette
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Re: Getting the syncro back on the road

Post by ajdenette »

well after not being able to start the van at the auto parts store trying to get the charging system tested as the battery wasnt charging and none of my alternators tested out :roll: (I dont like the new tester I dont have any faith in it). I cleaned all the grunds replaced the trans ground strap, cleaned everything in the main charging loop she started fast so that wasa good start. sonow the alt light is behaving normally so thats a good sign. the van is loaded with parts to sell at transporter fest here isto hoping we get there and back safely. :D
Alex

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Re: Getting the syncro back on the road

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So did we get back safely? I was going to check in on you but celebrating the end of my fall project got in the way.
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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ajdenette
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Re: Getting the syncro back on the road

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I made it home fine on one battery with the head lights on all the way :shock: the battery even had just under 11 volts when I got home but a rebuilt altinator is on the shopping list.
Alex

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Re: Getting the syncro back on the road

Post by fusername »

Awesome! Please remember to recharge my batteries asap, lead acid don't like to sit discharged, and one of those was already in fading shape..

Should I post up some of that chase video:lol
give a man a watch and he'll allways know what time it is. give him two and he can never be sure again.

Things are rarely just crazy enough to work, but they're frequently just crazy enough to fail hilariously.
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