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2020 New Build - Case Preparation

Murbella – Day 42 – New case prep and cleaning!

Posted on 2020-06-16

So today was all about prepping the new case and making sure some of the basic tolerances are there as well as some of the problems I found yesterday get fixed.

2020 New Build - Case Preparation
2020 New Build – Double Thrust Cam Bearing – No tang recess

The as I do with all prior builds, I need to mod the case just slightly to allow for the use of double-thrust cam bearings instead of the single-thrust stock setup.

2020 New Build - Case Preparation
2020 New Build – Case Preparation – Recess made

I basically use a tiny file to slowly remove material enough to allow the tang to lock into the case. No, that’s not a crack. Just a slight scrap on the surface. Nothing to worry about there.

It is never perfect since I eyeball it and do it by hand, but it has worked well in the past.

2020 New Build - Case Preparation
2020 New Build – Bearing Check

So all of the bearings seem to have oil galleries that line up with the saddle oil holes. I may check the one in more detail, but I think that most are perfectly fine.

2020 New Build - Case Preparation
2020 New Build – Case Preparation – Distributor gear fitment

The new distributor gear seemed to be tight going through the bore but once in it moves smoothly. I can’t remember how difficult the gear was on the 2019 new build.

2020 New Build - Case Preparation
2020 New Build – Case Preparation – Different plenum stud

The FI engine case hardware is a bit different, especially when needing to mode a Universal case. The main thing is that the one rear stud needs to be larger, as it goes up and through the plenum and locks inside of it. A real pain in the ass to remove it since you have to remove all of the nuts and split the 2 plenum halves just to remove it.

I ended up just removing the stud from the AJ case so I wouldn’t have to go find one to buy. I’ll need a replacement late down the line.

2020 New Build - Case Preparation
2020 New Build – Case Preparation – Different plenum stud

II know VW had to make the Type 1 case work for this, but this just seems like an area where problems can occur if that seal breaks. Now I removed an oil stud sealing nut from this so that’s what I’m going to replace it with. I’ll make sure I put some aviation sealant down below to ensure that is as closed as possible.

2020 New Build - Case Preparation
2020 New Build – Replacing the problem stud

Yesterday’s initial case inspection indicated the plenum would not properly fit on the studs. I was going to ream out the bore on the plenum mount point but I decided to pull the stud and then replaced it with the one I removed from the rear for the longer one.

Sure enough, there’s just a slight defect in the straightness of the stud. Replacing it solved the problem.

2020 New Build - Case Preparation
2020 New Build – Case Preparation

Everything worked and it all mounts well. I screwed the stud in deeper and it should now all work well.

There wasn’t a whole lot else do do. I shaved a bit of metal here and there. I could have spent hours on it if I really wanted to but I sure as hell don’t.

I washed up the case with Dawn detergent and just used the garden hose to rinse the case halves and then galleries clean.

Since this is a new case, I didn’t feel the need to do my usual trip to the car wash to use the high temp power washing.

2020 New Build - Case Preparation
2020 New Build – Case Preparation – Sun drying

All of the water got blown out withe compressed air and I left it all to dry more in the sun.

I eventually decided to use some parts cleaner on the inside a bit, cleaning the sump area a bit more as well as all of the journals and bores as a last clean pass.

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