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Old 01-05-2019   #376
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Re: Bluebell the 900e Amigo

Quote Originally Posted by timmycm850 View Post
Hi Peter

On the gears hat you received that don't fit, is the gear that fits on the crankshaft much thicker by about 8mm, I'm wondering if the gears you recieved are for a 100gl engine which has a different oil system.

Tim
Hi Tim, I think the gears are actually the same, the chain would fit either set and the gears will actually fit; both on the crankshaft and the camshaft. The drawback is that the central boss on each is thinner (I'll double-check with images tomorrow). A thick spacer came with the kit but I can't see any combination of placements that aligns properly.
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Old 07-05-2019   #377
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Re: Bluebell the 900e Amigo

Quote Originally Posted by Classicandy45 View Post
The mechanic who fitted the overhaul kit, messed up first attempt, complaining the spindle threads were made of plastercine (but just looked mushroomed by application of hammer to me!). Anyway, a 3bolt spindle, and another overhaul kit later and job was done.
Having just dismantled my pump I can sympathise with the mechanic.
The threads are made from Plasticine and a 34 year-old pump does not come apart according to the book instructions.

After trying to get away with my soft-headed hammer I gradually had to go up to a big, heavy thumper and consequently the threads on the shaft, although usable, are a bit manky. I also fell victim to the broken flange on the side housing...I have an escape plan for that.

But it crossed my mind that possibly a brand-new, three-bolt pump could be salvaged for parts because they can be bought quite cheaply from some online sellers......cheaper than the bearing overhaul kit. It's just that being pattern parts it's possible that the dimensions of the internals are different.

Where did you get your three-bolt spindle from Andy?
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Old 07-05-2019   #378
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Re: Bluebell the 900e Amigo

As mentioned above, here are most of the components of the water-pump. I've now managed to extract one of the woodruff-keys which seemed permanently embedded and I'm soaking the pump body in a mild solution of phosphoric acid and degreaser. I already cleaned out the thermostat-housing in the same way, but I'm being careful not to leave it too long; I only want to remove the rust and salt deposits and not to dissolve the whole assembly.

I'm trying the same technique with the radiator, but I think I'm safe to leave that longer term. The radiator has the advantage that because it is buried so deep and protected by cowlings it has sustained no significant external damage to the fins; unlike modern cars where I always find that dealership garages helpfully flatten the fins with the powerwash at every service.

I was going to use the chain of my new, mis-ordered timing-gearset on the old sprockets as they don't seem worn. But there is a bit too much side to side movement so the 850 set will go back on eBay and I'll order a new 900e set.

I didn't plan to get so deep into this at this point but like the rest of the van the engine seems to have suffered neglect and bodged repairs which might as well be fixed properly whilst I'm at it.
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Old 09-05-2019   #379
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Re: Bluebell the 900e Amigo

Better to do it while its out, rather than later.

Good work

D
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Old 12-05-2019   #380
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Re: Bluebell the 900e Amigo

Quote Originally Posted by timmycm850 View Post
Hi guys

100gbc is an 850 sport coupe (series 2/3) block and the engine number is normally on the machined face above and to the left of the timing chain cover, the seven or eight digit number cast into the block under plug 1 is a block part number and often the 100gbc blocks start with 4 and end in 141, the heads should also be cast with 100gbc in the middle of the top of the exhaust flange area, the coupes would normally run with a weber 30dic carb with two venturis at 23mm each, The 30dic carbs from series 1 850 coupe will have a smaller venuri size of 21/23, so running with a 30 ICF wont give you the full 47 or 52 hp and also you may lose a bit of the low torque(?) of the 100gf van engine as the 100gbc camshaft timing is longer and the carb is only a single choke.

ive never heard of a cast iron 850/900 head, if poss please show image of it. intruiged?

Gary, 850 coupe accelerator cables are slightly shorter than 900t types, you can replace the outer sleeve only of the accelerator cable as this normally corrodes, a metre from a bike shop is normally enough and you can carefully remove the solid ends from your own sleeve, sand your existing inner cable with a bit of oiled 400 grade paper to remove any surface corrosion before fitting the new sleeve, you dont have to remove the whole cable to do this just the rear outer piece.

just to fill you in i purchased my first 850 in 1989( an s3 coupe), since then ive not been without one and now have
1966 s1 coupe
1970 lombardi
1973 s3 spyder
1979 900t purchased 2015 i think
gamine
Hi
I've finally found the engine number - top left above the timing chain cover as suggested. It is quite faint and had a thin layer of grime over it hence why it was easily missed.

Stamped above the engine number (original by the way) is 100 GF .000 - so the GBC block casting number ties in with what had previously been suggested about most of the later blocks being stamped GBC regardless of where they ended up.

Reading the Haynes manual the GF engine has a 7.9:1 compression (the GBC is 9.5:1). From what I've read elsewhere on the Internet the lower compression should make it more compatible with unleaded petrol - less risk of pre-detonation etc.

If correct (can anyone confirm?), I'm happy to live with fewer horses in favour of the ease of being able to fill up at the pumps without worrying about additives etc.
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Old 12-05-2019   #381
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Re: Bluebell the 900e Amigo

Quote Originally Posted by Gary50 View Post
Hi
I've finally found the engine number - top left above the timing chain cover as suggested. It is quite faint and had a thin layer of grime over it hence why it was easily missed.

Stamped above the engine number (original by the way) is 100 GF .000 - so the GBC block casting number ties in with what had previously been suggested about most of the later blocks being stamped GBC regardless of where they ended up.

Reading the Haynes manual the GF engine has a 7.9:1 compression (the GBC is 9.5:1). From what I've read elsewhere on the Internet the lower compression should make it more compatible with unleaded petrol - less risk of pre-detonation etc.

If correct (can anyone confirm?), I'm happy to live with fewer horses in favour of the ease of being able to fill up at the pumps without worrying about additives etc.

based on this additional info. as i understand it.

100gbc engine castings when supplied in 900t when new will have 100gf on the engine stamped number above the timing chain and also the head will have 100gf cast in the cylinder head by the exhaust.
100gbc engine castings when fitted in coupes from new will have 100gbc stamped by the engine number and cast into the head.

let me have a look at my engine that didnt seem to perform like a 100gbc should and i will get back to you. this might be the end to my mystery. lets see
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Old 13-05-2019   #382
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Re: Bluebell the 900e Amigo

Pete, you are correct 're pump spindles... after first failure, I had a new unused 3 bolt pump, and we rescued the pump by using the 3 bolt spindle.
Gary, my 84 pandora been running on unleaded fine for last 5yrs,no linking or starting difficulties. In that time it's done thousands of miles all within the speed limit!
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Old 20-05-2019   #383
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Re: Bluebell the 900e Amigo

I'm still waiting for some of the parts for the water-pump and I've made a repair to the casing I damaged on removal by using epoxy-adhesive and a tailored steel plate to strengthen it. A big package of mainly rubber-based parts arrived whilst I was on holiday. So I could make a decent start on the front suspension, amongst other things, but I must first get the engine back together.
My acid-bath did its stuff on the radiator-shroud whilst I was away and it's left with a thin film of iron-phosphate and just needs priming.
The new timing-chain is a really good fit in comparison with the old one....all the sagging has gone and I've since removed the engine-sump so that I can replace the timing-chain cover now that I've fixed the studs back in properly.
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Old 23-05-2019   #384
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Re: Bluebell the 900e Amigo

I'm still plodding away at sorting everything in the engine bay which led me to doing a few pieces of welding which I couldn't get at until the radiator was removed.
I've also pulled out the metal pipework that runs back to the heater and I'm not decided on how to replace it. It could easily done using copper pipe and fittings like @Vin but I might extend it so as to remove the need for the complicated rubber pipe pictured, which conveys the hot water from the thermostat housing to the solid heater-pipe as I am unable to find a new replacement. I might even do it in plastic PEX pipe because this is fairly flexible and I have a load left over from plumbing the house; the only issue there is that the fittings are very bulky.
Every day I sort out a few details of the engine-bay and amongst other things, today I coated the pump-body and thermostat housings in clear epoxy paint; at the price they cost new it is worth protecting them from corrosion for as long as possible.
I've also got the sump and other metal parts soaking in the bath of phosphoric acid so that by the time the pump is rebuilt and ready to fit everything should be de-rusted and ready for use at the same time.
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Last edited by fiat500; 23-05-2019 at 22:58.
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Old 02-06-2019   #385
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Re: Bluebell the 900e Amigo

There's been quite a bit of work to be done on my 500 which has brought the welder out of storage and taken me away from the van for a week. Whilst in the mood for metal-shaping and melting I thought it was time to make a start on the engine undertrays. There aren't many pieces of this left intact and the most original remaining item is a backwards-facing scoop which directs the hot air towards the rear of the vehicle; you can see new and old side by side.
I've had guidance from an excellent blog-page here: https://spannerdude.wordpress.com/pa...lown-diffuser/

But I'm not as interested in emulating the original construction so possibly found an easier way to make it. It's so good working with entirely new steel when it comes to welding. The item did take about three hours to cobble-up and I did the final tacking together with the three component parts bolted in-situ so that it would end up a good fit.

Obviously I'm very pleased with this part because it would surely be impossible to obtain a new one. The next item will be the main undertray.
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Old 03-06-2019   #386
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Re: Bluebell the 900e Amigo

Impressive fabrication & welding
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Old 4 Weeks Ago   #387
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Re: Bluebell the 900e Amigo

The main engine undertray supplied with the van was a simple piece of sheet-steel which was roughly cut to fit and bore no ressemblance to the correct one. So I consulted the web-pages referred to previously for clues.

I made something similar to fit;. It is relatively straightforward in shape but takes quite a bit of work to get the geometry and alignment right.

The original section of tray which fits above the exhaust silencer had been patched-up with a combination of aluminium/bitumen tape or flashing and some rough fibreglass. It was simple to make but involved a fair bit of butt-welding as it was a bit complex for me to simply beat into shape out of one or two pieces. If there is sufficient clearance I may supplement this with some spare aluminium heat-shield that I've been keeping for such a purpose.

It looks like the original trays were fixed with self-tapping screws and matching captive "nuts". As the new ones are tailored to fit I was able to weld M6 nuts so that it can all be secured using some of my surplus stainless, hex-socket screws.

I still need to get some rubber so that I can rivet a sealing-flap where the undertrays meet the engine sump, but I'll do that when it's all in-situ and the engine is fully assembled.
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Old 4 Weeks Ago   #388
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Re: Bluebell the 900e Amigo

Have you found a supplier for the rubber sealing flaps yet?
(It's on my to do list but haven't looked yet.)

With the sealing flaps are they supposed to touch the engine to create a full seal or just get close? I can't tell with Connie's old under trays, as they have been repaired several times and left a gap - this could have been wear or meant to be that way.

Would you use rubber to seal around the exhaust as well?

Also, is the only purpose of the under trays to stop heat from the radiator getting back into the engine bay? If yes, I'm hoping that the ducting that I've added to Connie will remove the need for a tight fit between the engine and under trays - or remove the need for them completely (other than the ones used for the ducting).
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Old 4 Weeks Ago   #389
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Re: Bluebell the 900e Amigo

Quote Originally Posted by Gary50 View Post
Have you found a supplier for the rubber sealing flaps yet?
(It's on my to do list but haven't looked yet.)

With the sealing flaps are they supposed to touch the engine to create a full seal or just get close? I can't tell with Connie's old under trays, as they have been repaired several times and left a gap - this could have been wear or meant to be that way.

Would you use rubber to seal around the exhaust as well?

Also, is the only purpose of the under trays to stop heat from the radiator getting back into the engine bay? If yes, I'm hoping that the ducting that I've added to Connie will remove the need for a tight fit between the engine and under trays - or remove the need for them completely (other than the ones used for the ducting).

I'm not even going to try to find the original sealing-rubber although I've some fragments left. Something like this should work:

https://www.ebay.co.uk/itm/Medium-BL...frcectupt=true

It looks like they were tightly against the sump but not close to the exhaust. I suspect that the idea was that the engine-bay should be as tightly sealed as possible from below so as to encourage all the air to enter via the side-louvres. But that's a bit of a futile aim given that sealing around the exhaust was not attempted.
I have no experience of VW Beetles but I've read that they have a well-sealed engine-bay which has a significant effect upon cooling so I'm going for maximum airtightness to below.
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Old 4 Weeks Ago   #390
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Re: Bluebell the 900e Amigo

For the last four weeks I've been anxiously waiting for the repair kit for my water-pump, which has been holding up the engine refurbishment. Today I found that it had been delivered ages ago whilst I was in Italy and was sitting in a pile of logs in the garden. Everything was waiting for assembly so it followed that I should assemble it.

It's quite a tricky to work out the correct order to fit all the pieces but after a lot of dry-runs and faffing about it's now in one piece again.

It's a relief to have saved the hundreds of pounds that a refurbished or new pump would have cost me and good to know that this very important component functions like new again. OK, it doesn't look like new, but that's not my way of doing things, but with new seals and bearings, new gasket, keys, re-threaded shaft and new nuts, some epoxy repairs to the casing and clear epoxy paint to protect the aluminium, it should be good for another 35 years.
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