Steve's unending Progress thread, Air compressor setup recommendations Options

[stephenaki]

OK, this will be the thread that I keep updated as I make progress. I showed up at 0800 at Christoph's place and he was ready for me with a not so glamorous chunk of metal that is my cars heart and soul.

With a little assistance, we loaded it into my Toyota Sienna, not quite I envisioned a mini-van for, and I was headed back to the house. Upon getting home I had to first make coffee then clear out some space in my tiny German garage. So that everyone has a frame of reference to the area that I am working in I have enclosed this lovely 4x6 glossy of my garage in Germany.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747638.1.jpg)

And, for those of you not familiar with the Toyota Sienna, a shot of the engine in the back of the van. There's a lot of room back there for the motor but, it is awkward to get in and out of when loading a motor.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.2.jpg)

Now to summarize what was accomplished on the 4th of July, engine brought home, tin, impeller and housing, exhaust, cylinder head and cylinders removed. I had difficulty removing the impeller hub. OK, I didn't get it removed, will need a puller and I don't have one unless anyone can give me any ideas how to get it off without a puller.

Now for the requisite pictures of the motor unmolested.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747640.4.jpg)

Now based on the initial tear down two problems presented it self first the primary issue with a lack of compression...HOLY SHIT!!! Here is what I found.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747641.5.jpg)
(IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif)
Now the cylnder itself was not pitted, it had a build up of corrosion but otherwise in good condition. So I was thinking, maybe I can just clean hone and replace the piston. Well that thought went out the window when I pulled the cylinder directly opposite to it. As you can see by the photo, problem #2.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.6.jpg)

More importantly, where did that piece of metal go? An initial look behind the piston shows a knick in the inner portion of the crankcase.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.7.jpg)

I will see if there is more significant damage when I split the case; so it begins and were off to a rocket start here at the 914 follies! Stay tuned for the next exciting episode of "never buy a car sight unseen" later in the week! (IMG:style_emoticons/default/happy11.gif)

Gonna go shower and start working on the motor some more. Plan is to have it completely torn down befor the end of this weekend. I will load up some pictures to my photo bucket album and post the link a bit later.

[ThinAir]

This is a great thread. I really appreciate all the photos and descriptions of what you are finding.

Can you post a link to the article on Jake's site that you've mentioned? I seem to have a collection of 1.7s that could be candidates for 2.0 conversions. I'm really glad to know about DPR since I have a 2.0 with a frozen rod bearing (don't ask) and I know that when I eventually rebuild this engine I'll need their services.

[stephenaki]

This is a great thread. I really appreciate all the photos and descriptions of what you are finding.

Can you post a link to the article on Jake's site that you've mentioned? I seem to have a collection of 1.7s that could be candidates for 2.0 conversions. I'm really glad to know about DPR since I have a 2.0 with a frozen rod bearing (don't ask) and I know that when I eventually rebuild this engine I'll need their services.

Sorry it took me so long to respond but I have been a bit busy at work as of late and not exactly in country. The link is:

http://forums.aircooledtechnology.com/showthread.php?t=2328

you may have to sign up for a free membership to view the forums but he has a lot of great info there.

On a different note, the engine component parts were sent for balancing last week and should be ready. I ordered the gaskets, seals, etc from Jake and they are on the way. Unfortunately, the rebuild is now on hold as I got told this afternoon to pack my stuff cause I'm heading to a country that shall remain un-named to stand a team up to do??? Needless to say I will be gone until mid-October if not longer. Just when I thought I was making progress!! (IMG:style_emoticons/default/av-943.gif)

I had managed to avoid a third trip to Israel but by doing so got tagged with this new mission. Son of a bitch! I am gonna get a quote from Christoph to see how much he'll charge me if I just give him the rest of the parts and let him finish the rebuild and install the engine. I head out this Sunday so need to make some quick arrangements as my wife is currently stateside and my middle son, he's 19, is here. He gets to live alone for a couple of weeks until my wife gets back.