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Polo motor build for junkyard coupe 58367

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  • Click image for larger version  Name:	IMG_3077.JPG Views:	0 Size:	201.2 KB ID:	105749
    Ready to drive the new plug Bill made home.
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    Took a lot to drive that in there. Bill recommended welding over it but we'll see...
    Click image for larger version  Name:	image_60840.jpg Views:	3 Size:	200.6 KB ID:	105752
    Full mock up with the chain box.

    Click image for larger version  Name:	image_60839.jpg Views:	3 Size:	230.0 KB ID:	105751
    Bill, also made this nice plug for the distributor hole.
    Click image for larger version  Name:	image_60841.jpg Views:	3 Size:	226.3 KB ID:	105753
    Thanks for looking!
    Justin
    Last edited by JTR70; 06-15-2019, 07:35 PM.
    Justin Rio

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    • Wow that work was involved indeed. Clever !

      Roy

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      • JTR70
        JTR70 commented
        Editing a comment
        Thanks again Roy! It was the answer I'd been looking for.

    • Finished out lower valve covers and onto the uppers:
      Click image for larger version  Name:	IMG_5516.JPG Views:	0 Size:	158.2 KB ID:	108544 Many an hour spent hand sanding and shaping in and around those relief shapes and I've chased it as far as I'm going to go.
      Click image for larger version  Name:	IMG_5514.JPG Views:	0 Size:	164.3 KB ID:	108545 A few pin holes remain and am adding drops of silver paint to soften their appearance but I'm not too concerned at this point. I just need to be done now.
      Click image for larger version  Name:	IMG_5139.JPG Views:	0 Size:	170.5 KB ID:	108546 Moved onto prepping the upper covers for final paint. These had been powder coated from the factory and it was extra tough to remove especially down in those reinforcement shapes. I tried bead blasting them clean but I had to sit on one spot way too long to get back down to the metal. I gave up on that and resorted to torching it off and then a wire brush follow up which worked well enough.
      In the process I lost some of my JB weld pit filler but will go over it again later.
      Click image for larger version  Name:	IMG_5144.JPG Views:	0 Size:	116.0 KB ID:	108547 Epoxy primered and shot with a coat of Sahara beige. The original paint on these was a beige base with a silver top coat so I'm replicating that as close as possible. Back filling the pits next.
      Click image for larger version  Name:	IMG_5462.JPG Views:	0 Size:	119.8 KB ID:	108548 Pocks refilled and sealed over with more epoxy. One more coat of beige to even it all out then the final silver base then clear coat.
      Last edited by JTR70; 04-23-2020, 07:25 AM.
      Justin Rio

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      • Completing upper valve covers:
        Click image for larger version  Name:	IMG_5499.JPG Views:	0 Size:	139.0 KB ID:	108550 Fogged one silver base
        Click image for larger version  Name:	IMG_5517.JPG Views:	0 Size:	154.3 KB ID:	108553 Final clear coat...Done!
        Click image for larger version  Name:	IMG_5519.JPG Views:	0 Size:	143.5 KB ID:	108552 Detailed shot of the lopped off end. Unlike the lowers which I'm leaving raw the paint on the uppers allows me to get that last 10%.
        Click image for larger version

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ID:	108551A shot of the original finish on a removed section. Beige base with a silver overlay. Not an exact match but close enough with a similar flavor.
        Click image for larger version  Name:	IMG_5506.JPG Views:	0 Size:	164.8 KB ID:	108554 Cam towers and the covers are now ready for installation. A very long, frustrating, expensive and time consuming ordeal but these top end parts are finally finished. Onto the next deal.

        Thanks for looking!
        Justin

        Last edited by JTR70; 04-23-2020, 07:44 AM.
        Justin Rio

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        • Justin

          You should laser scan those or make some casting forms, before you put the engine together. I am sure that there will be a time in the near future when people will want covers instead of welding them up . You could do a 2D casting and then do the inside machined later. Pick up on the center of the four holes in the castings for reference and build the interior from thoes points.
          Pushed around since 1966.

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          • JTR70
            JTR70 commented
            Editing a comment
            Hey John, That would be a great idea if there was any demand but there really won't be. 99% of Deans motors run the much earlier cam towers and chain boxes. Not only that but the way I shortened these later 964 towers is not the way its normally done so the final bolt pattern on the lower cover would be different. Justin

        • Beginnings of exhaust header fabrication:
          Click image for larger version

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ID:	108968Just purchased pre mandrel bent Stainless Steel exhaust tube sections to fabricate a header set from. I'll probably end up needing at least two more of these but this pair gives me a starting point for now.
          Click image for larger version  Name:	IMG_5614.JPG Views:	0 Size:	146.8 KB ID:	108967 Custom stainless steel flanges to fit these heads will have to be fabricated first. I'm having my machinist cut me out a set based on this pattern next.

          Thanks for looking!
          Justin
          Last edited by JTR70; 05-31-2020, 08:04 PM.
          Justin Rio

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          • You need a JDSquared tube bender. I used one on my test cell headers and it was super. The manual bender and a digital level you can make anything
            Pushed around since 1966.

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            • JTR70
              JTR70 commented
              Editing a comment
              I'll have to add that one to my tool wish list John.






          • Click image for larger version  Name:	IMG_5805.JPG Views:	0 Size:	140.9 KB ID:	109041 My Machinist had a question concerning the pipe fitment into the flange so I stopped by to confirm. He had the basic pieces turned out of some stainless stock. Pictured above. I'm sure he'll have these knocked out by weeks end.

            Thanks for looking!
            Justin

            Justin Rio

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            • Exhaust flanges complete:
              Click image for larger version  Name:	IMG_5866.JPG Views:	0 Size:	100.4 KB ID:	109107
              Turned out gorgeous! Bore matches the exhaust port and flange tapers away at the center to allow the air to keep flowing.
              Click image for larger version  Name:	IMG_5868.JPG Views:	0 Size:	108.3 KB ID:	109109 Friction fit with the tube to allow set angle adjustments as the header build continues. Have the option of welding these two together from the inside...
              Click image for larger version  Name:	IMG_5869.JPG Views:	0 Size:	109.3 KB ID:	109110 Or just weld it on the outside.
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              Click image for larger version  Name:	IMG_5867.JPG Views:	0 Size:	115.8 KB ID:	109108 Off to pick up the other three this afternoon, pay the bill then begin fabricating the intake flanges.

              Thanks for looking!
              Justin
              Last edited by JTR70; 06-19-2020, 07:30 PM.
              Justin Rio

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              • Click image for larger version  Name:	IMG_5876.JPG Views:	0 Size:	165.1 KB ID:	109114
                Picked up the rest of the order this afternoon. Pricey little order here but a lot of set up time to create each one. Oh well, another item in the done column. Now onto the intake side.
                Thanks for looking!
                Justin
                Justin Rio

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                • ARP fastener sets for the bottom end.
                  Click image for larger version  Name:	IMG_6119.JPG Views:	0 Size:	178.3 KB ID:	109363 Stepped up big and purchased the entire ARP line of hardware and fasteners for the 911 engine.
                  Click image for larger version  Name:	IMG_6131.JPG Views:	0 Size:	162.6 KB ID:	109364 Had to make this heavy lift in stages so my first purchase was their head stud kit,
                  Click image for larger version  Name:	IMG_6132.JPG Views:	0 Size:	170.8 KB ID:	109365 Like fine silverware. Super high quality . Love the bullnose tips...
                  Click image for larger version  Name:	IMG_6124.JPG Views:	0 Size:	231.2 KB ID:	109366
                  Once I had a chance to digest the head stud purchase it was then onto their crankcase perimeter stud set.
                  Click image for larger version  Name:	IMG_6125.JPG Views:	0 Size:	204.1 KB ID:	109367After the perimeter set it was their Case through bolt set for 964. Just as gorgeous the rest of their stuff.
                  Last edited by JTR70; 07-21-2020, 08:38 AM.
                  Justin Rio

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                  • Click image for larger version  Name:	IMG_6123.JPG Views:	0 Size:	202.8 KB ID:	109369 And finally their bell housing stud kit.
                    Click image for larger version  Name:	IMG_6121.JPG Views:	0 Size:	201.9 KB ID:	109370 This is of course set up for a six cylinder so I'll have some hardware left over for spares.
                    Click image for larger version  Name:	IMG_6120.JPG Views:	0 Size:	234.0 KB ID:	109371All the hardware needed to hold the bottom end together. Nice to have this one in the done column. Onto the next purchase.

                    Thanks for looking!
                    Justin
                    Last edited by JTR70; 07-21-2020, 08:37 AM.
                    Justin Rio

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