The SLOW engine rebuild begins - Page 2

Tonks4x4 · 11-08-11, 11:44 PM

The core plugs are a bit of an arse to get out of these engines!
The holes are not the same diameter right through the block wall. There is a lip behind the plugs that the plug buts up to and you have to be very careful not to crack away to much of the casting when getting them out.
You can't just tap them in the centre to shrink them away from the edges. I have tried drilling in the centre and then using a slide hammer with no success. It is difficult to fold the edge down with a hammer and chisel without damaging the casting.
So I ended up carefully removing the core plug material in 2 opposing places with the dremmel. You can then tap the two halves towards each other and gently pry them out.

Megsy · 12-08-11, 12:01 AM

just wondering why you haven't stayed with the 3b block and just re-built that with rods. It would have been a lot cheaper and will easily make 420 bhp with the right turbo ?

20vcqdriver · 12-08-11, 12:02 AM

Looks like i am going to have fun getting the core plugs out. At least I know about the lip now. Hope new ones go in a bit easier.
Measured bore wear and its less than 2 thou which is amazing as the lip (like coxys) made me think it was a lot more. As forged pistons normally require a larger clearance I hope this works in my favour. Going to be a while before pistons arrive, though still plenty to be getting on with.

Tim C · 12-08-11, 01:32 PM

Quote:

Originally Posted by 20vcqdriver

Looks like i am going to have fun getting the core plugs out. At least I know about the lip now. Hope new ones go in a bit easier.
:

I've found they usually start to tip if you hit them in on one side, with a bluntish piece of metal so that it doesn't pierce it. Then they can be pulled out.
Depends how long they have been in there of course

.

They do go in a lot easier than they come out. A little too easy for my liking.

Good luck with the build Dave.

20vcqdriver · 12-08-11, 04:54 PM

Quote:

Originally Posted by Megsy

just wondering why you haven't stayed with the 3b block and just re-built that with rods. It would have been a lot cheaper and will easily make 420 bhp with the right turbo ?

This one came along by pure chance so not one to miss an opportunity...and I can still drive the Cq whilst i am fettling this one, the swap over should then be able to be done in a week (not upto Brians speeds

)

20vcqdriver · 22-08-11, 08:22 AM

OK, things have come to a halt as 2 hours before I was due to go on hols I went flying whilst running with the dog. Result is a cracked rib and broken wrist. 'You Plonker Rodney'

BIGGYIN · 22-08-11, 06:15 PM

Plonker.

jogi730 · 22-08-11, 09:23 PM

That's cruel. Don't kick the dog!

20vcqdriver · 22-08-11, 11:11 PM

Quote:

Originally Posted by jogi730

That's cruel. Don't kick the dog!

Actually he was very concerned and insisted in licking me non stop whilst I lay on the ground waiting for the world to stop spinning

My fault trying to do a quick left turn on very slippy grass.
Tried mowing the lawn tonight and now wishing I hadn't. Keep looking at the block and tempted to pick up the allen head sockets but Lynn would kill me..

20vcqdriver · 24-08-11, 11:48 AM

Back for proper cast today (see pic), Pete and Ellen want to stencil the Audi rings onto it

. So not able to do much but have inspected the block and the only real issue is the tops of the bores (see pic) There is no way I'll get piston rings past that without damage so some extra work going to be needed as Tony did on Coxy's.

12-08-11, 12:02 AM	#13
20vcqdriver 4 ring whore! Classic Audi Club Member Join Date: Dec 2007 Location: Wirral Posts: 3,910	Looks like i am going to have fun getting the core plugs out. At least I know about the lip now. Hope new ones go in a bit easier. Measured bore wear and its less than 2 thou which is amazing as the lip (like coxys) made me think it was a lot more. As forged pistons normally require a larger clearance I hope this works in my favour. Going to be a while before pistons arrive, though still plenty to be getting on with. __________________ Coupe quattro 1986:-~450bhp + loooong list of mods! Audi A7 Bi-TDI SLine Black edition 2015 mapped to produce 600lb/ft torque! Audi S4 4.2 V8 cabriolet 2004:-

22-08-11, 08:22 AM	#16
20vcqdriver 4 ring whore! Classic Audi Club Member Join Date: Dec 2007 Location: Wirral Posts: 3,910	OK, things have come to a halt as 2 hours before I was due to go on hols I went flying whilst running with the dog. Result is a cracked rib and broken wrist. 'You Plonker Rodney' __________________ Coupe quattro 1986:-~450bhp + loooong list of mods! Audi A7 Bi-TDI SLine Black edition 2015 mapped to produce 600lb/ft torque! Audi S4 4.2 V8 cabriolet 2004:-

22-08-11, 06:15 PM	#17
BIGGYIN 4 ring whore! Classic Audi Club Member Join Date: Mar 2009 Location: Merseyside Posts: 7,976	Sod's law. Plonker. __________________ q90 B2 Type 85 - q90 B2 Type 85-PROJECT-ABY 20vt KARL. Injection is nice but I'd rather be blown

22-08-11, 09:23 PM	#18
jogi730 jogi Classic Audi Club Member Join Date: Dec 2007 Location: Luton, Bedfordshire Posts: 1,689	That's cruel. Don't kick the dog! __________________ 1985 Audi 90 quattro 20v turbo with some tweaks

24-08-11, 11:48 AM	#20
20vcqdriver 4 ring whore! Classic Audi Club Member Join Date: Dec 2007 Location: Wirral Posts: 3,910	Back for proper cast today (see pic), Pete and Ellen want to stencil the Audi rings onto it . So not able to do much but have inspected the block and the only real issue is the tops of the bores (see pic) There is no way I'll get piston rings past that without damage so some extra work going to be needed as Tony did on Coxy's. __________________ Coupe quattro 1986:-~450bhp + loooong list of mods! Audi A7 Bi-TDI SLine Black edition 2015 mapped to produce 600lb/ft torque! Audi S4 4.2 V8 cabriolet 2004:-

11-08-11, 11:44 PM	#11
Tonks4x4 4 ring whore! Classic Audi Club Member Join Date: Oct 2008 Location: Huthwaite, Nottinghamshire Posts: 2,607	The core plugs are a bit of an arse to get out of these engines! The holes are not the same diameter right through the block wall. There is a lip behind the plugs that the plug buts up to and you have to be very careful not to crack away to much of the casting when getting them out. You can't just tap them in the centre to shrink them away from the edges. I have tried drilling in the centre and then using a slide hammer with no success. It is difficult to fold the edge down with a hammer and chisel without damaging the casting. So I ended up carefully removing the core plug material in 2 opposing places with the dremmel. You can then tap the two halves towards each other and gently pry them out.

12-08-11, 12:01 AM	#12
Megsy Grown up member Classic Audi Club Member Join Date: Feb 2008 Location: cheshire Posts: 229	just wondering why you haven't stayed with the 3b block and just re-built that with rods. It would have been a lot cheaper and will easily make 420 bhp with the right turbo ?