Guydo's 2004 vw cup mk2 Engine rebuilt by Hotgolf

Marts going to sort the new ABF pistons to fit the block checking height etc and then figure out how much to remove from the crown and how much to enlarge the pockets .

 

So this unused distributor arrived from eBay today 40 delivered for a mint Bosche unit .
Very happy

 

Yesterdays report from Gas N Gears

Hey up. So, the block is on the stand, and the crank is polished. I've honed the bores and 1 has a faint mark going down from what looks like a sharp ring edge. Personally, I'd leave it as it is and just use it. I've seen worse and used even worse than that lol So, crank is a 92.8mm abf job. Journals are spot on, and so far I've plastigauged the mains to 1.5-2.5 thou clearance which is great. I've put 1 rod/piston in and the abf piston is 1.9mm proud. Now you can really only take 1mm out of the valve pockets so these aren't going to accept 12mm lift cams, but the issue could be the amount taken off the head. I may need to cut the seats deeper to give us some extra clearance. But lets do some more sizing and measuring first.

Hoping for some pictures soon but holidays may delay .

 

Pedantic Old Fart should be Capitalized.
It is my Title not a statement of fact!


Or is it?lol

 

I put a not The lollollol

 

Crikey!

I had better get my finger out then as this will mean I only have about 6 to 9 months to sort things!
I need to send a wiring diagram for the rev-limited ignition system. I have pre-set it a 8200 rpm.
I also promised a wiring loom for the 5th injector! I still need to ask John for some high quality cables.

 

Hopefully the car will be ready for some track action in the summer if funds keep trickling into the car fund lol

 

So got some news from Gas N Gears today

Whoever bored these bored the original bush. The bronze is only thin in the steel backing and theyve gone through.

Pictures from Mart





Fortunately Im having Mart rebuild this engine as Id have used the rods as they were ok when they came out but hoping to use this car for more often trackdays now hence getting a professional to look at it , also its far from a standard KR engine .

I enjoy sharing my adventures with Golfs but Im not bothered what people think of my work as Im just having fun.

 

The Schrick camed head is also with Gas N Gears getting some tlc and mods to work with the Modified KR block and ABF pistons

 

At least you know you will have a properly sorted engine now

 

Suitable rods sourced by Mart and will be with him soon , hes working on the cylinder head while waiting for rods .

 

Oh so many yummy shiny goodies....

 

Not so shiny bits just cleaned

 

So failed to post this report from Gas N Gears when it came but better late than never .

So, did a little more today. Due to the excessive skim on this head, plus the position on the pistons the best solution is to cut the seats deeper and shorten the valves by 1mm. Then, deepen the pockets 1mm and remove 1mm from the piston face, chamfering the edge like a JE/Wossner.

On stripping the head I found this:






And this is after the little ends had been rebushed .



Thats all for now but I did sort my broken photobucket links today thanks to advice by Justin thumbup

 

So the head needs some work


Ready for action





Sorted next cams where polished by Mart as theyd got a bit damp sat on my bench for 2 years


Hotgolfed/ Gas N Gears lighten flywheel thank you very much


And bottom end being reassembled.


Also my version of a baffled gated sump bellow was improved by Mart .
My plastic trap doors bellow have been replaced with metal hinged doors .

 

Just had a message the engine is done Hotgolf has done his stuff

Now I need to sort myself out and get down to South Wales and pick it up but gutted that I cant take my GTiEngineering RE2000 engine down for a refresh as hes to busy

 

Liking a lot...