Took the 2.0 to North east Machine shop last week.

their link

Here's the news:

Check align bore: Good

Turn and polish crank: One over

Magna flux (or whatever it's called) to test for cracks: Good

Install threaded galley plugs: No problem

Soak and clean case: Nice and shiney!

Measure con rods: two are good, two are bad.

Find and balance two new rods. Can you recommend a replacement?

Find bearings "one over".

$425.00 for the work and the rods. Sound reasonable?

I have about 600 stock rods... I should have two that are decent enough for rebuild. 40 bucks each as cores.

As for the price you paid- I'd dsay its a little steep, especially for a non TIV specific shop to complete the work. I don't charge that much to do those things mentioned.

"Find" bearings. How hard is that? You look in the catalogue, you order the bearings. "Magnaflux"? I have yet to see a T4 crank that needed to be checked for cracks, but I guess you could spend the money. Never had one that needed an align bore, either, so we just look for beaten spots in the case. I haven't yet seen a functioning T4 rod that couldn't just be rebuilt. Seen a buncha bent and broken ones, but the ol' Mk 1 eyeball can see that. Nice work to have done if you have the money, but you were kinde "upsold", IMO. The Cap'n

Imagnaflux cranks before having them turned into strokers and I do find a few that are cracked... very few.

Align boring is being more common practice these days because all cases are approaching 30 years of age. The TIV case generally doesn't need much attention.

I would say that if this shop isn't TIV specific they may have missed some of the things that are actually real problem areas while trying to do the things associated with "Other" engines in the machine shop..

I'd like to know why two of the rods were "Bad" myself.

3 of my 4 cases needed align boring. the rear main crush was gone. I did get lucky on teh thrust, it was OK. T-1s get it bad in this area. chevy guys need to magnaflux everything

Jake: are the brazilian over size bearings OK? should I worry about them?

I asked them to Magna-flux the case, not the crank.
Look close at this picture and you may understand why I wanted the align bore "checked". If he had to re bore the case, I probably would've looked for another one.
I should have been more specific about my question re: the con-rods. I know that they make after market rods and I know they make rods that cross referance to other applications, like Chevy rods or rods that come out of a water cooled VW. Though, now I will just get the rods from Jake.
As to the bearings. This is gonna be tough to make any sense out of but try to follow me:
If the Crank is turned down, the align-bore size is stock and the "inside" of the bearing is one over. If the case was bored, the "inside" of the bearing would be stock and the outside of the bearing would be one over.
Am I thinking right?
If two "main" journals had to be turned, and the two others were ok, Would you turn all four and buy a complete set of four "undersized" bearings or two and two? 2stock and 2 undersized?
And as Jake said, the price for the work was a little heavy, I'm not sure I'd want to order the bearings though them.
Jake I'll call right now.

wtf happened to that rod?

QUOTE (Aaron Cox @ Sep 8 2005, 09:26 AM)

wtf happened to that rod?

[QUOTE]

I don't know
I think it got starved for oil
"Ridden hard and put away dry"

Ummn, you can't magnaflux a case...... Only ferrous materials can be magnafluxed- They are lying bastards if they told you they did this process to your CASE.. I inspect cases for cracks with eddy current checks if they are questionable or with liquid penetrant and a black light... You can only magnaflux things that can become magnetic.

So you need main bearings 021 198 483A or RAT 4038 in German.. This is STD OD (case) and .010 ID (crank)

If you want first over OD (case) thats .020 and STD crank thats an 021 198 491 or RAT 4020.

As for those rods- yeah they are toast and i would not trust that crank either... it takes ONE HELL OF A LOT to bend a 2 liter rod...

Brazilian bearings are .001 larger ID out of the box than German.. The German are used in all my engines due to material content and tolerance.. The German bearings even weigh more in grams, hence them having more lead content.

I get pretty tired of being the last resort for people- call me first and you won't have to worry about this crap...

BTW_ I'd like to see pics of the galley plugs installed in the case- if they went too deep with the threading it can shut off the oil to two of your oil passages and destroy the engine in 30 seconds... I see it all too often.

TIV specialist work on TIV engines- no one else.

Whoa, guys!
Don't be so tuff on the old guy! I was just asking.

#1 I used the term "Magnaflux" so everyone would understand what I was talking about. Dye Test is the term I was looking for, but I forgot, ok?

#2 This is not the origonal crank! The origonal was TOAST!! "Type I" Eyeball check told me that. And about 4 of the Club 'teeners confirmed it in my progress thread! It's a boat anchor! The used one I found just needed a little turning.

C. The VW guy around here couldn't even look at this motor until December. When I asked around I was refered to this shop by 11 out of 15 inquiries. I'll be glad to do business with anyone here, but I didn't feel like mailing a case and a crank. It seems a little expensive. I like to deal with local people whenever I can.

#5 When I took the engine in, the guy doing the work just glanced at it and knew it was a Type IV from twenty feet away. I get the impression it's a good shop. I'll live with that decision.

Jake, did you get my e mail?

No email.. If it was sent through the store rebecca will take care of it.. I'm outta the store now. I got it all set up, running smoothly and ASAP I was back where I belong and only answering technical questions through the store.. Becky will take care of you swiftly and accurately, she is awesome!

QUOTE

I'll be glad to do business with anyone here, but I didn't feel like mailing a case and a crank. It seems a little expensive. I like to deal with local people whenever I can.

I don't do anything local... Last engine I built for a local customer was 4 years ago! I receive cases and machine work from all over the world from people that want the job done right- DHL just dropped off a case today from Costa Rica... I have had them shipped to me from as far away as Australia!

Think shipping is expensive?? Let one goof bite you in the ass and you'll make up a new definition for word expensive.... The shop may be just fine,and I hope they are but to me ALL non specific shops are "Guilty until proven innocent"... Check everything 3 times..

e mail sent

Dave,
no email received..

Eight fourty five PM eastern time. No email from rebecca, yet.

jake:
the type 4 store does not recognize those part numbers

Dave,
I just looked in the queue for store emails and I did not see yours.

Send it to me
productdevelopment@aircooledtechnology.com

I'll take care of it.. Email has been wacky lately.

Sean,
I saw your question... The numbers/parts you need are on this link

http://www.aircooledtechnology.com/store/p...&cat=261&page=1

Use the pull down tab to see the bearing sizes, the suffix in Parentheses is the RAT part number, the same as the ones I posted earlier in this thread...

great thanks
align bore price please? I have 2 more cases. teh other 2 gt done by Don at Bug Patch in Santee

?

Well, the case is done at the shop.

Grind the crank and pull the cam gear etc,

tap/ install the oil galley plugs

cold tank the case and check for cracks

check for alignment (straight bore)

rebuild a used set of connecting rods

$605.00 with tax