Just another overhaul thread

[Al Schober]

Why do we happily spend hours trying to save a part that can be replaced with new for $0.25 (or even $25.00)?

[Surcouf]

Why do we happily spend hours trying to save a part that can be replaced with new for $0.25 (or even $25.00)?

the keepers? I was not trying to save them, I was just trying to remove the valves without bending them or damaging the guides

[Surcouf]

So head is saved! Machine shop was able to drill out the 2 rusted / broken spark plugs, without any damages to the threads, so no damn helicoils!
Head clean, flatness checked within spec. Done in less than 2 days, 70$. R&R Machining in Warwick, RI. great shop!

Spent 30 minutes with shop owner chatting and going through all the weird engines and motors they have all around the shop, some very nice and rare pieces (not just muscle cars blocks, even if these are nice).

So thank you Jcwright for your offer, but it seems that I will not need your spare head!!!

I need to cut those bolts now, take the flywheel and the cover out. At that point, there should be no more disassembly required. Time to seriously start cleaning, stripping, painting etc... the fun part no?

[jcwright]

Hello Surcouf.

Well I keep trying to loan or give away tools and parts from my rebuild, so far without success.

I'm glad to hear that you could salvage your head. Mine will have to wait to be adopted by anyone else in RI or nearby who is looking for one.

Best regards,

Jack.

[Surcouf]

Hello Surcouf.

Well I keep trying to loan or give away tools and parts from my rebuild, so far without success.

I'm glad to hear that you could salvage your head. Mine will have to wait to be adopted by anyone else in RI or nearby who is looking for one.

Best regards,

Jack.

Do not let those tools get buried too far... What have you used to install the output coupling back? (TOOL_08_137). I was able to remove it with a classic automotive puller, but I do nto have anything to put it back. I was going to make one, but if you have the official MM's one...

[jcwright]

The tool you mention was one that I didn't buy, though in hindsight it seems penny-wise and pound foolish.

Two items that may be of use are the stud pullers (both sizes that are needed) and an engine stand (with the modifications needed for the A4). Send me a PM if you are interested in borrowing them.

Jack.

[Surcouf]

The nice way did not work... so Dremel was out. Flywheel cover came nicely, the 2 broken bolts too.
Baby steps....

[Surcouf]

Lazy...

So after 2.5 months doing nothing on the engine, it is more than time to go back to it. My fault, as I tried to train for a marathon (mid-life crisis), and take care of an engine, on top of the daily job => failure. But a famous virus cancelled the marathon, so I felt I had to get back on the engine...

I have only started with the misc parts requiring painting... so multiple cleaning and degreasing, rust prevention, and first coat of POR 15 done in the basement (my wife hates me). Not sure what is inside that paint... but one of my plastic glove got damaged at one point and I just cannot get that paint away from my hand... mineral spirit, scrubbing etc ... none of the usual trick is efficient. A good sign !!

[Surcouf]

Paint questions for you guys: after painting do you remove paint from the spark plug seat? Do you clean the plug threads for any paint that may have leaked?

Thank you!!

[JOHN COOKSON]

The spark plugs are grounded to the head. Having clean threads and seats for the plugs can only help with proper grounding.

Acetone on a rag will remove almost any paint from your hands.

ex TRUE GRIT

[Surcouf]

Questions for you guys: when I removed the engine head, it was hell to lift the head out of the studs. So regarding the cleaning of all "through holes" that go through the head for the studs, I would like to make sure to remove any crap (paint, gunk, corrosion etc..) from the previous 40 years (and also any fresh paint):
- how do you clean the holes in the head where all the head studs go through? acetone+brush?
- does somebody know the exact diameter of those holes? what drill bit should I run there?

thank you !!!

[ronstory]

Acetone on a rag will remove almost any paint from your hands.

ex TRUE GRIT

... not POR-15, you will need to wear it off. I now always use gloves with that stuff.

[Surcouf]

... not POR-15, you will need to wear it off. I now always use gloves with that stuff.

that is what I am discovering with my black and white hands at the office! How do you clean your brushes after using POR 15? is Acetone good enough for that? Mineral Spirit failed...

[sastanley]

When I painted my engine, I left an old set of plugs in the head to keep the threads clean. I bet if you just screw a spark plug in and out a few times, it will clean the threads right out.

[ronstory]

that is what I am discovering with my black and white hands at the office! How do you clean your brushes after using POR 15? is Acetone good enough for that? Mineral Spirit failed...

Just discard them, I used the foam brushes and higher quality Harbor freight brushes (which is an oxymoron) and are still cheap.

Also, if you let POR-15 get in the lip of the can where the metal lid attaches, you can forget about opening it again. What I do when i open the gallon, I have the metal quart paint containers from home depot on hand. Then I paint everything I can possibly paint and then pour the remnants carefully into the fresh quart containers and seal. Good for about a year if done well.

if you are using the quarts, keep a couple of the metal pint containers on hand as well.