West) OKRASA ENGINE BUILD PROJECT TASK SEQUENCE LIST
Last Update: 9/27/13
Task Sequence (
through = completed):
36-hp engine case for second-over (.50) main bearings and connecting rods to
standard size bearings at NW Connecting Rods.
Wolfsburg West’s Okrasa high-performance kit, NOS FRAM canister oil filter set-up and Abarth full-flow stainless steel performance muffler.
new stock-size piston and cylinder set, overhaul gasket set, new set of 8
pushrod tubes, new pushrods and Viton synthetic rear main seal.
centrifugal advance distributor for non-vacuum tapped twin Solex carburetors from Ed Fall. Ed supplied a restored
and re-curved a February '59 date stamped Bosch VJR
4 BR 8 distributor to fit a (BTDC) 7.5°to 24.5°@ 3500 RPM advance curve.
stroker crankshaft, forged, 69.5mm,
4340 steel alloy, connecting rod and main bearing journals have been
nitride hardened to HV 500, counter weighted and
high performance camshaft, 234 degree duration at .040" (or 227
degree duration at .050"), .345" lift, 24 degree overlap.
reproduction “OT” crank pulley at slightly smaller than stock size.
6-volt, 200mm late VW
style clutch, SPG pattern 8-dowel hole flywheel and corresponding “collar” type pressure
plate and clutch disc.
vintage engine main bearing set, .50 (second over) / standard sizing for
use of brand-new crankshaft in my old case.
5 new main bearing dowel pins, Porsche 356/912 high-performance gland nut
and Porsche metal flywheel to crankshaft seal, 3 Porsche camshaft hex
bolts with lock plates and 3 Porsche camshaft dowel pins.
Wolfsburg Motorwerks shop press to remove timing
gear, spacer, distributor gear, oil slinger,Woodruff keys and C-clip from old 36-hp
“0” size 912 camshaft gear.
standard-size pushrod bearings.
install 912 cam timing gear on Okrasa camshaft.
new high-flow oil pump.
and test fit engine cylinder cooling tins to work with Okrasa
install manifolds and dual Solex carburetors,
fan housing, fuel lines and throttle linkage in preparation for modification
of fan housing to accommodate welded-on throttle linkage bellcrank and captive nuts for FRAM oil filter
canister & relocate coil mount.
new aluminum oil cooler.
throttle linkage bellcrank
onto fan shroud after final test fitting.
necessary fittings and lines for use of FRAM canister oil filter.
main bearing, timing gear, spacer, distributor drive gear and c-clip on
crankshaft, then install in engine case.
cam into engine case and test cam timing gear clearance, swap out until
finding one that meshes correctly.
fit and clearance connecting rods by removing material from rod caps until
all interference issues are resolved.
material removal on all 4 connecting rod caps as closly
parts to Action Autoparts: Machine Shop for
machining; flywheel and clutch assembly for balance and roll-pinning the
pressure plate to the flywheel , install dowel pins to permanently mate Okrasa camshaft with 912 timing gear & balance 4
distributor drive and distributor in left engine case, clocked at #1 TDC.
- Upon return from connecting rod
balancing, perform final assembly of the bottom end with crank at #1 TDC to sync with distributor and install cylinder
pistons and cylinders, determine barrel shimming requirements to attain ? to 1 compression
necessary size barrel shims from Wolfsburg West.
and install push rods using shims provided from Wolfsburg West.
receipt of barrel shims from Wolfsburg West, test fit, verify compression
ratio calculations and if OK,
perform final installation of pistons, cylinders, cylinder heads with new
pushrod tubes and seals. If not
reorder correct size from Wolfsburg West.
and test fit engine cylinder cooling tins to lengthen sheet metal to
accommodate additional barrel shim width if necessary.
satisfied with engine cooling tin modifications, deliver all pieces to
Seattle Powder Coating for a coat of semi-gloss black.
original fuel pump and install with fuel pump spacer.
new oil pump with original pump cover modified to allow for thicker oil
new aluminum oil cooler.
fit Abarth full-flow stainless steel muffler and
modify as necessary to align flanges with modified shimmed head port
return of the cooling tins from powder coating, attach to engine, install
FRAM oil filter, oil lines, carburetor linkage.
new oil strainer and sum plate, oil filler baffle, oil filler seal and oil
filler to case.
seal at top of generator stand and install generator/fan assembly.
complete exhaust system.
spark plug wire conduit tube with wires fed through, clamp to Okrasa cross-over tube with stock clamps, install
spark plugs, secure all the connections.
flywheel and shim for correct end play, once correct, install new gland
nut and torque to 400 foot lbs, install clutch disc and pressure plate.
20-minute break-in run on test stand.
new 6-volt starter bushing and new starter in transaxle bell housing.
OKRASA engine in car, fire up and drive off into
the sunset with a huge shit-eating grin on my face!
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