Done for the future reference of all engine gurus worldwide. Should answer all questions in respect to how far out the 1.8T block can be taken to. Here we go now, enjoy! Green surfaces are VW factory faces, red surfaces are my own cut surface ground faces. And the all important measurements> Bore 81.00mm Stroke 86.40mm Base of bore to side of rod clearance at approx 80 degrees after top dead centre> 8.50mm. Base of bore to centre of rod at approx 80 degrees after top dead centre> 20.00mm. Average wall thickness of block through out(non high load areas)> 4.00mm. Distance between bores taken with a high quality vernier callipers> 8.98mm. Piston crown thickness> 6.32mm. Distance from bore wall to root of oil squirter thread> 3.96mm. (''root measurement'' as in root of the thread of banjo bolt that holds squirter in place) Average main oil way gallery's diameter> 12.30mm. Oil feed to head, average diameter> 6.20mm. Crankshaft oil way drilling diameter> 4.40mm. Average deck thickness, pretty uniform throughout> 10.00mm. Bore wall thickness to adjacent waterways ****4.50-6.00mm*** , **mainly 5.00mm** Block featured is a standard bore 1.8T AUG internal water pump forged crank type block with approx 50k miles. I hope these pictures and specs help everyone who is thinking of or in the process of building a great engine. I hope these pictures will put peoples minds at ease with any doubts they may be having when it comes to boring these babies out or planing the deck, tapping oilways for remote supplies, dry sumping,etc. One thing i was surprised at is the thinness of the bores to adjacent water passages, something to be taken on board and not ignored. Something to note is the piston and rod, they're from an earlier 1.8T, you may have noticed its not a sintered rod and the pin is 1mm bigger. But the dimensions and throw are the very same, as is rod profile. I stand by all of the above measurements.
wow! fantastic pictures to have better insight on what thicknesses and where exactly the thin areas are. thankyou sir. can this be made a sticky?
I`ve always loved cut-away mechanicals (studied a lot of them at college), but never found out how they are done...big ripping bandsaw, or something more precise?
9'' bosch angle grinder and a good eye is how i did it. linished all cut faces afterwards. thanks for the comments guys, and for making it a sticky, makes it all worth while
Can anyone think of any other measurements ive forgot? Donating this to a local college for use a learning tool in the next week or so, so i want to have all angles covered.
