Aircooled VW South Africa

That looks badass.

Reminds me of '80s/early '90s BMX chainrings.

N.

Hey Cal,

So you not building a 1776 anymore - with you buying 4Age's 90.5 pods and pistons???

Good luck man, hope it brings you joy...

90.5's for another future project.

Here is some of the clearancing done, bearing carrier had to be thinned to accomodate the crank cheeks, the area next to the sleeve opening has also been radiused to clear for the longer stroke.





Above and below the sleeve opening had to be notched to clear the rod bolts.

Forged 76,4 crank that will be duing duty on the front line.



With the clearanced rods attached.

These rods have been cleared to eliminate too much clearing of the engine case and weakining it.



These show how far it can be taken, but no more.

OEM sleeve has been machined to 1mm oversise.
The valves have also been unshrouded to match the larger bore 86.5mm. I have done some re-shapping of the chamber to aid flow, the step was also flycut and a 49cc combustion chamber was the result, final CR will be between 8 to 1 and 8,5 to 1 (TBC)
Don't ask the head is not cracked between the valves it was a mark left by the milling machine during operations.
The valves are stock size 35x32



BTW there is no need for the polishing in the combustion chamber, all that is needed is smoothness with no sharp edges.
That "chrome look" shine that many modifiers do and claim adds to HP is totall bull 30 seconds into the run-in and all that shine is gone.



Note the cross hatch of the walls essential to keep rings happy.

Inlet ports have had some reshaping done, again no "chrome look" shine here, as many do, just smooth no rough edges. I used my round port template and straightened the port directing flow directly over the valves.



BTW OEM valve springs to be replaced with HD singles as soon as they arrive from the US.

The dudes in the US puting 84mm strokes into OEM cases have balls, I beleive if things get too thin they break, luckely no clearing needed on the case roof, but it's close.

The Kadron manifilds needed to be notched to fit the heads



They have also been port matched

The resized cylinders have also received a lick of black hi heat paint, even if the paint does nothing, at least it looks better than seeing the rusty fins

Hey Cal,

Looking good man....

Wat heat paint did u use on those pods??..looks great

Happy building...

I use heat resistant Plascon in a aerosol can about R45 a can from the local Pick'n Pay