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Introducing Pompi - my first Kombi

Discussion in 'Members Rides' started by Gordon D, May 1, 2017.

  1. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    Thanks for the advice @KahunaKombi - all went well. Now just to do a bit of tidy and touchup on the bare metal and we're good as done :D
    2018-08-26 11.40.34_small.jpg 2018-08-26 12.30.19_small.jpg 2018-08-26 12.30.45_small.jpg
     
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  2. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,106
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    Bracken Ridge, Qld
    It's a bugger when they change the profile on the fins :mad: ..... no consideration to tinware needing to be there.
     
  3. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    It would be good to have the option of buying the extra tinware when you order the kit ... what could it be - $20/$30 max?
    Ahh well, it's all good now :D
     
    Last edited: Aug 26, 2018
  4. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    Well, despite it only being a short day today and a limited access weekend because of Father's Day tomorrow, I am quite happy with progress and feel I have hit a significant milestone ... WE HAVE ROCKERS!!
    But first ... in this shot of the newly inserted studs for the gearbox nose mount, you may have noticed that the studs were sticking out a little too much on the gearbox posts - because the studs were too long.
    gearbox close-up.jpg
    Originally, Gorilla Mechanic (the new name for whoever it was that worked on Pompi previously and just used whatever was to hand) had just used a couple of bolts that fitted (mostly) so they had to come out. I was told they needed to be trimmed but I think there was a bit of a measurement cross-up ... I was told the length difference in millimeters but the provider of information meant centimeters. So first task today was to address that ... while being as neatly beveled as the proper end I was quite impressed with my work ... and it meant I got to use yet another tool. Angle grinder for the win :D
    2018-09-01 14.02.12_small.jpg 2018-09-01 14.03.20_small.jpg 2018-09-01 14.26.31_small.jpg

    Next, on with the lower tinware/deflectors and in with the pushrod tubes and pushrods. Had to use a socket and gentle tap with a soft hammer to get those tubes in but all went smoothly
    2018-09-01 16.22.38_small.jpg 2018-09-01 16.22.45_small.jpg

    ... and then [drumroll please] on with the rockers!!
    2018-09-01 16.46.06_small.jpg
    They still need to be torqued and set but given that I was aiming for a 5pm finish and I tightened the last nut, rolled the engine onto its belly and then rotated the crank a few times to confirm the rods were pushing and the rockers were rocking and the valves were opening I was very relieved and more than a little excited :D
    2018-09-01 16.52.18_small.jpg
    Next weekend it is the heat exchangers and additionals as well as the torquing of the rockers and then gapping. I have just had a nice glass of red in celebration - end of September is looking pretty good :p
     
  5. Wayne murray

    Wayne murray Well-Known Member

    Messages:
    2,337
    Location:
    Seven hills
    Your rocking on Gordon:cool: keep them moves coming;).Party on at Gordon's . Nice work
     
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  6. David H

    David H Well-Known Member

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    3,839
    Location:
    newcastle
    You've earned the red;) & I'm sure you're enjoying your progress:D. Keep up the posts.
    Cheers
     
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  7. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,106
    Location:
    Bracken Ridge, Qld
    Well put Wayne :D
     
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  8. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    Well, a rare mid-week posting ... last night, for the first time in 4 months, the tinware was reunited with the motor. With a fair wind and smooth seas, there will be a significant difference to how the motor looks by the end of this weekend as I reassemble this jigsaw puzzle :D
    painted_parts.jpg
    Just don't look too closely at the quality of the painting ... this was more about neutralising rust and cleaning the tin :p
     
  9. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    19,106
    Location:
    Bracken Ridge, Qld
    Looks clean and super shiney to me @Gordon D :):cool:;):D
     
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  10. Wayne murray

    Wayne murray Well-Known Member

    Messages:
    2,337
    Location:
    Seven hills
    That's why we paint it Black:p . It looks good all the same.:)
     
  11. cbus

    cbus Well-Known Member

    Messages:
    11,263
    Location:
    sunshine coast
    As long as its a thin coat on heater boxes.
    Burns of with lots of smoke otherwise ;)
     
  12. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    One coat only ... and lightly sprayed
     
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  13. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    A little bit of progress today ... slightly hamstrung because I forgot to order the replacement Alternator Cooling Elbow back when I made up my original list and forgot to confirm it :oops:
    However, despite that, the engine has wings with shiny new screws as well as fresh new feet (replacement engine mounts) and new dipstick boot :D:D
    2018-09-15 16.58.41_small.jpg 2018-09-15 16.58.25_small.jpg
    2018-09-15 14.58.15_small.jpg 2018-09-15 14.58.38 HDR_small.jpg
    2018-09-15 14.57.54_small.jpg

    One thing that I remembered (just in time) was that I had bought pushrod tube retaining springs as they were missing on the old head. Like most things, opinion is divided on their necessity but I preferred to err on the side of caution - but it was a little frustrating. They are fiddly beasts and it took me a while to work out how they were meant to actually fit and be tensioned ... and as usual, once I worked out one head, the other was simplicity itself.

    In the interests of helping others and if you forgot which way the gap in the rocker stud mounts faces, here's the answer - the gaps face the pushrods and the wires are slotted into the slots - genius :)
    2018-09-15 12.31.28 HDR_small.jpg 2018-09-15 12.30.37_small.jpg 2018-09-15 12.31.50 HDR_small.jpg

    The rest of today's time was trying to piece together the tinware jigsaw ... I should've taken better notes on the disassembly :confused::eek::(
    Off to research now and see how far I can get before I have a hard stop because of the alternator cooling elbow :p:cool:
     
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  14. saabman

    saabman Well-Known Member

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    4,770
    Location:
    Goulburn
    That’s looking realy good. Won’t be long now :)
     
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  15. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    Oh I had to laugh today ... yesterday afternoon at the point where I was just about to stop I spent the better part of 45 minutes trying to fit two pieces of the tinware on the engine and started tearing out what little remains of my hair. Last night a little light went on “Oh, you mean the FRONT of the engine ... which is the other end of the bit I’m looking at!”. This morning, two minutes and two bits of tin are where they’re meant to be :confused::rolleyes::D
    Damned rear engine motors going and confusing me :p
    Today was only a couple of hours and the primary task was popping on the front of the cooler housing (and getting that damned dipstick tube to go into the damned rubber boot through the damned tight hole) and then trial fitting the alternator to see what bits I am missing.
    2018-09-16 12.17.12_small.jpg
    Hopefully I can get my alternator cooling tube this week and then we're cracking on next weekend :D
     
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  16. KahunaKombi

    KahunaKombi Super Moderator Staff Member

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    Gordon, Homer moments allowed Doh!!!!!!!!!!! :confused::eek::rolleyes:;)
     
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  17. Gordon D

    Gordon D Active Member

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    271
    Location:
    Brisbane
    Took the weekend off last week ... needed a little break and couldn't really progress cause of this little bugger:
    2018-09-29 10.11.56_small.jpg
    But today? Today is a different story ... today we made progress and a fair amount of it too ... feel like I am coming out of the back straight and into the final curve.
    Achievements today were the fitting of the alternator (elbow, belt and all); installation of the heat exchangers and then refit of the primary tinware.
    2018-09-29 10.54.28_small.jpg 2018-09-29 12.28.44_small.jpg
    After that was gapping the rockers ... and I am fairly sure I am going to have to fit longer pushrods :eek: ... but let's see how she goes after a bit more fitting. So it was on with the valve covers and then the front main tin and lower heat deflectors
    2018-09-29 14.19.11_small.jpg 2018-09-29 16.06.02_small.jpg
    Tomorrow will see the dizzy, clutch and maybe ... just maybe ... the remating of the engine and gearbox :rolleyes::D:cool:
    Gonna be a big weekend ... but I would rather have had her on the road for Old Bar. Oh well, there's always next year ;)
     
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  18. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
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    Location:
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    What else would you be doing @Gordon D :rolleyes: the glorious weather and AFL Grand Final yesterday :D ....... then today rain & cold + NRL Grand Final :) ....... I'd prefer to be playing mechanics :cool::eek:
     
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  19. Gordon D

    Gordon D Active Member

    Messages:
    271
    Location:
    Brisbane
    Another Homer moment today. Honestly, the amount of times I have had to repeat steps again, I feel like I am back at Uni again :p
    Today's was getting in the dizzy. Everything looked good - position of rotor related #1 lead related to TDC related to mark on flywheel related to valves fully closed related to piston head just visible through sparkplug hole ... except the timing mark on my fan was out by exactly 90º ... and once more, worried that I had managed to knock something critical, I was tearing my hair out (really, I am going to be permanently bald after this exercise). So, stopped, had some lunch and while chatting to Dad a little light went on ... didn't I take the fan apart to clean it all? D'oh, I had put the front ring of the fan assembly back on one bolt anticlockwise out :oops:;)
    So, on to the more critical piece of advice needed ... I went to put the clutch back together and it looks like the new friction plate I got for box is not quite the same as the one that came out. Do I have a Frankenstein issue again? The cone on the friction plate looks longer and differently profiled to the one that was there as well as the spring portion deeper. Is this an issue?
    2018-09-30 13.16.43_small.jpg 2018-09-30 13.17.42_small.jpg 2018-09-30 13.18.39_small.jpg
    Also, when I assemble the flywheel, friction plate and pressure plate, there is a gap between the pressure plate and flywheel ... does this just disappear with compression as I bolt the pressure plate down?
    2018-09-30 13.31.37 HDR_small.jpg 2018-09-30 13.32.21 HDR_small.jpg 2018-09-30 13.32.29_small.jpg
     
  20. Wayne murray

    Wayne murray Well-Known Member

    Messages:
    2,337
    Location:
    Seven hills
    Nice work Gordon,I'm glad I'm not the only one having a big weekend of work,o_O;)missing old bar:(. Someone at KC has to hold the fort together:rolleyes::)and look like the place is still a hive of activity ;):D while everyone else is letting there hair down.:):cool:
     
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