Milly the 1979 Westfalia Berlin Deluxe Bay Window Camper Van

[chrisradioman]

Been thinking of one of these for a while, decided to bite the bullet today & buy one:-









I've also had my eye on one of these:-
http://www.bluebird-type2.co.uk/Split%2 ... terior.htm

Halfway down. As I only have one high seat bulkhead again I'd need to modify it. I'd also need it to be quick release so I can still swivel the front seat.

[chrisradioman]

Tudor Morgan has just been & taken Milly's engine to the hospital. He's thinking now of cutting out the piece that's broken from one of the other cases & welding it back into Milly's engine, like a kind of transplant. This is good news & means I get to keep the original engine.

Tudor Rang me just now, the case is finished the rod has broken through the hydraulic lifter bores too, the cam is knackered & so is the crank. I basically need a complete engine, I'm off down his workshop in the morn to take some pictures.

Called down Tudor's today to see the damage:-


The hole in the case



The damage inside the case



The engine bits laid out



Damage to No 4 cylinder



Damage to No.3 cylinder



No 3 conrod




No. 3 piston

[chrisradioman]

Crank



Camshaft



Cylinder head valve seat No1 cylinder.

For anyone that hasn't heard of Tudor Morgan, this is his workmanship:-

http://www.karmann-coachbuilts.com/technical/tdi.htm

This isn't even his speciality. He specialises in air cooled

[chrisradioman]

Picked up another engine today, its a CU block, very good condition, a good crank, good barrels, good pistons. I just need a new cam & followers.
Some more pics of the collected parts:-





CU code 2.0l engine that can be modified by Tudor Morgan

[chrisradioman]

Now I have a good case, a good crank, good barrels & pistons, good heads & all the auxiliaries are good. I just need now a good cam & new hydraulic followers.

He's going to use the best 2 heads, bead blast them, reface the valve seats replace the valve guides, clean & rebuild them. He'll use the best 4 barrels & pistons, horn the cylinders, clean & bead blast them, then grind them into the heads & new piston rings.

Measure check the crank, polish the ground surfaces, fit new bearings & clean it.

New cam & hydraulic followers.

All new bearings, seals etc.

Once its all rebuilt with new oil etc. He'll dry run it on the bench.
He'll set all the valve clearances, timing, check the compression, do a leak down test, oil pressure test & fuel pressure test.
Finally put the engine in the van & get it running for me.
I can't wait.

This is a type 1 he's just built for a customer that's ready to go out:-



Tudor Morgan if any one wants his no. let me know.

[chrisradioman]

Tudor Morgan has decided now to use the Porsche Engine, He's happy with all the parts I have just needs a new cam & followers now.

[chrisradioman]

Called to see Tudor Morgan today, fair play he's done loads already.
He's bead blasted my cylinders, these now will be horned & cleaned 6 times:-


Pistons will be polished, the ring groves cleaned out, cleaned 6 times & fitted with new rings:-


The heads have been bead blasted, next he'll fit new valve guides, re-cut the seats, cut the valves & lap them in. The springs will be tested for tension & everything checked to make sure its in spec. They will also be fly cut where the cylinder fits in & the cylinders lapped in. All the studs will be replaced & the heads then cleaned 6 times.


The case will have the type 4 syndrome oil pick up damage welded & machined, all the studs will be replaced & my original engine No. stamped back on it, the Porsche No will also be left on the case. Tudor doesn't bead blast the case as there is too great a risk of some of the material being trapped in the block. It will all be washed out & cleaned a further 5 times & all the oil ways & galleries air blasted clear:-

[chrisradioman]

All of the small ends, con rods, gudgeon pins etc. spec up as new, so will just be cleaned a further 5 times & reassembled on the crank with new big end bearings. The crank is all balanced & in spec, so will be cleaned a further 5 times & assembled with new main bearings & this this time the conrods will be tightened down properly:-


Tudor Morgan has a few engines on the go, one of them is a type 4, he even takes the trouble to repair & paint the heat exchanges:-



He even welds & re-cuts the main bearing on type 1 engines to get rid of the end float:-

[chrisradioman]

Tudor sent me some pics of the engine last night:-

[chrisradioman]

Tudor Morgan has been busy busy busy, today hopefully I'll have some more pictures to share with you tomorrow.

[chrisradioman]

Some more pics for you, the studs and dip stick tube being removed.
All successfully done, cases going to be welded today to have the
broken oil pick up bosses built up:-

[chrisradioman]

Tudor has had the case welded, he's done a superb job.

Next stage is to mount cases in the mill, square them up exactly, spot
face the welds, drill to the correct clearance and tapping sizes, then
tidy up the shape of the welds, in order to bring things back to
original.

Then the cases should be ready for the final clean and can move on to
the crank and con rods, ready for bottom end assembly.

Will keep you posted.

[chrisradioman]

Slight detour from the engine, I bought some red cable ties for my fire extinguisher hose:-


Got myself a set of Goodridge brake flexies, cheers Davey, this is a job for after the engine is running & if I get time before the MOT:-



I have 3 of these:-


& 1 of these:-

[chrisradioman]

Went to see Tudor today, he's had all my new bits in:-

[chrisradioman]

My M8 Cooper came down today for me to do some work on the rust bus, I fitted a tow bar electric plug, replaced his brake light switch & greased his nipples wink wink, nudge nudge:-