Project S2, it's a biggun!

[JM1962]

Looks like a rust free car from those photos, if the drivers side is as good it should make a good car when its cleaned up. Keep the photos coming.

 

[333pg333]

Definitely one of the worst condition motors I've seen in a long while. Amazed that anyone could let it get to this state.
Good luck on your quest. []

 

[bertelli_1]

Please! 'rat look' is somewhat over used in VW circles, generally describing a rotten car for sale at an elevated price. If I ever describe my cars as rat look please shoot me. Several times.

Anyway, the 'good' cylinder head is now with Promax, who are going to arrange getting it sorted. At the very least it needs a skim but may need a bit of welding due to corrosion.

The bottom end seals are in stock at promax so I'll start assembly soon.

 

[Northern924]

So good to see a '44 getting the full treatment in the present climate.

Really looking forward to seeing this one back to its former glory, always sad to see another car die but its all in a good cause []

 

[bertelli_1]

I wouldn't call it 'the full treatment'! Although I do intend replacing all the engine seals & gaskets, clutch, belts etc so it should be a 'fit and forget' project that has very few post build niggles (some are inevitable). The red bodyshell has now gone to another pcgb member, I suspect there will be very little left after he's finished with it!

 

[bertelli_1]

I finally have the white car home now and the head is back, first, a pic of the head - the finish is awesome & well worth the expense (gulp!), compare it to the previous pic,

Now the body work. I've started the cleanup & have done some before and after shots of the worst side. My missus bought me a pressure washer, it made the work so much quicker & easier. It still needs further cleaning & a polish but the car will be sitting on the drive for a while yet so there's no point doing the job twice.

Thats what I call dirty & you haven't seen under the bonnet yet! Next on the list is to recon the 2 sets of brake calipers & sell off the spare ones which should pay for some more engine parts.

 

[DivineE]

Damn! People say I have endless optimism. You certainly have some guts to look at that engine in the first pic and think.. yeah I could use that! Amazing work thus far I'm dead impressed!

 

[bertelli_1]

Overdue update - I have spent some time rebuilding the head but finally got bored after the 3rd pass with the grinding paste. Valve grinding is a very tedious task. Fortunately my clutch arrived which gave me something else to do. I also bought some other seals inc an RMS, oil cooler kit & a thermostat - much easier with the engine out!

Surprisingly I found another problem, I had noticed the cooler takeoff has about 3 tubes worth of sealant on it. When I removed it I found a large crack, so the original engine will be donating another part. I've probably used more parts off the 'damaged' engine than the 'good' one now!

 

[944cop]

Just wanted to say good for you mate when my waterpump went I ended up doing a top end rebuild I seriously thought about scrappin mine especially grinding in the new valves lol but in the end decided to keep it on the road and knowing all the work that went in to getting mine back on the road just makes me appreciate it more. I love my 944. Next years job bodywork and respray.

 

[bertelli_1]

I swapped the takeoff tonight, fitting the one from the original engine which had the cam tensioner problem. When I took out the oil pressure valve I found, you guessed it, another problem! A tiny piece of swarf had become stuck in it, holding the valve open. This would have caused low (maybe no) oil pressure & could well be the reason the engine was stripped - its not the first time I've seen the exact same thing.

And here is a pic of the swarf next to a 13mm socket for comparison. It doesn't take a lot to ruin an engine.....

 

[912UK]

nice to see a car coming to life and I am with you on your project make a nice car for your self for as little out lay as possible nice one.. good luck

ref your paint you can mop ( trade talk ) the paint with some G6 and G10 and then clay and polish it will come up nice I am sure..

 

[bertelli_1]

I've used G12 (I think) before & got excellent results. What are the ones you mention?

 

[bertelli_1]

Time for an update now all the snow is gone - it was (below) freezing in the garage! The cylinder head is finally assembled, here are some pics of the pitting on the valves & seats before grinding -

And lovely smooth (and out of focus) finish afterwards -

The amount of time it takes to refurbish a head cannot be underestimated, fortunately I don't charge myself labour. Once the valves & seats were done I could temporarily assemble the head in order to measure the valve spring lengths, then determine where each shim should be fitted (I had a mixture of 1.6 & 2.0mm shims). Then it was all taken apart again, cleaned again before final assembly. The finished head -

Thats another big step forwards, next up is actually getting the engine in the car.

 

[bazhart]

Those head gasket pictures demonstrate exactly the point I raised in the "potential engine seizures" posting recently showing the path that the coolant would spill through without ever reaqching the rear of the engine.

Baz

 

[bertelli_1]

Indeed and I've seen a lot worse! They are at the age now that potential owners should really be looking for evidence of a gasket change, along with belts, clutch & cam inspection.

 

[bazhart]

Totally agree Bertelli_1 and that advice is what promted the original postings - basically that deterioration of a head gasket that is still sealing the combustion could short circuit the coolant path and lead to the type of seizures we have often seen but never previously explained.

However they last over 10 years so I don't think there is anything wrong with the standard gasket - but it is good adavice to change it wherever you are if it has not yet been replaced in the last 10 years say.

Baz

p.s. if any of my postings sounds like I am immitating an Italian I aapologise - just like in the previous word - a letter a has satarteda appeaaaaaaaaaring alla over the place following some water coming on to my desk anda keyboarda - this sentence being the one I didn't go back anda edit! Quite funny really!

 

[Diver944]

ORIGINAL: bazhart

alla over the place following some water coming on to my desk anda keyboarda

Just how old is the gasket on that keyboard Barry? []

 

[barks944]

Itsa Super Mario!

 

[bertelli_1]

I know, the engine STILL isn't fitted. But its ready, just a matter of sliding it into place & bolting it in. Here's a few pics anyway - the car is ready for the engine, bumper removed, crossmember mounted to the engine & its finally clean. I've also included before & after shots of the inner wing so you can see just how grubby it was!

 

[colin944]

Good luck and keep up the good work! At least you don't have to do loads of welding on it. Should be a nice car when it's done.