Air Cooled VW - Boring and Decking for Larger Cylinders

[@VintageVolks]

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[@gregglockee4699]

I've been a machinist for 30 years, and I will say that is how you do it. Good job.

[@VintageVolks]

Thank you. I thought long an hard about how to build this jig and make the process as efficient as I could.

[@philipcable7518]

Good to see the centre line of the crank being used as a datum. So many times I see the case joint used wrongly.

[@VintageVolks]

It is definitely easier to use the case parting line. I suspect that is one reason people do it.

[@j.robertson7403]

Great work! Can’t wait to send in my case for machine work!

[@eklein3904]

You can tell when professionals are at work......cheers 😉

[@thomaspollock4274]

Very interesting video, will have to search your sight for more. I am looking to get my 1500 bored out.

[@cmiimages]

I'm not into Vdubs (VW) as such but nice old school engineering and machining.

[@KA4UPW]

It was strangely satisfying to watch. Would have minsed seeing all four. Really missed no seeing the final product.

[@rekylbrems]

Nice work! I wish my case was also decked like that when the cylinders where bored.

[@steverives3060]

How does this effect the threaded stud holes at the circumference of the bore? Boring for 94mm cylinders even worse?

[@whydahell3816]

Now that is an awesome set up.

[@toddshreve2971]

Nice to see how it’s done, more videos please

[@triariicat8448]

how do know how much take off when you're machining the deck surface ?

[@dclongoria1]

I like to see how vw cases are milled dor bigger specs

[@Nigel2Zoom]

Love these kinds of videos!

[@shanewelch1006]

Very professional video... thank you and look forward to seeing more... I subscribed 👍

[@seanpettit6410]

what is the purpose of decking the top of the bore?. thanks

[@winstonsmith5307]

I don't know anything about machining. Question: How did he know his milling tool was centered over the hole when made the cuts for the jugs in the case? Sorry if this is a stupid question; please be merciful.

[@VintageVolks]

We have a centering tool that we use to center the spindle over the hole before putting the cutter on.

[@joshcosta423]

Top notch work

[@jadney]

When you deck the cylinder bores, do you machine all 4 to the same distance from the crank center line? Or do you just machine enough to clean up the surface?

[@VintageVolks]

We machine all 4 to the same distance from the crank center line. In fact, the boring jig has flats on the main bar so we can measure to make sure all 4 decks are spot on before taking it off the mill.

[@teddlovell367]

At 3:30 am I seeing the mill column shifting? If so, does it matter?

[@VintageVolks]

That is an effect of the image stabilization on the hand held camera. If the quill was shifting, there would be funky groves in the bore that is being cut. It would not be a good thing.

[@chickensoup5452]

Wow... where did you get those end mill cutters? Or are they custom made

[@VintageVolks]

I made the jig for holding the case on the mill table. The cutters are from Gene Berg. I think Rocky Jennings makes a set as well. They're pretty simple to make though.

[@chickensoup5452]

Hey, do you guys ever enlarge the oil galleys on single relief cases? Ive got an h5 case and cant find much info on how to do so. Thanks

[@VintageVolks]

Its not worth doing. By the time you pay for it, you could have sold that case and bought a large gallery case and probably saved a few bucks in the process.

[@martingarage5800]

Do you made the line boring kit?

[@VintageVolks]

Yes, I mad the bars and the towers they mount to on the mill. I just finished a set for 356/912 and 36hp cases as well!

[@1fastbuggy502]

How can I get a set of those bars you use ?

[@VintageVolks]

Sorry, those are shop designed and built. I don't know of anyplace that produces anything like them.

[@1fastbuggy502]

@@VintageVolks You should market them.

[@VintageVolks]

Thanks, that's flattering, but, there is way too much work that goes into building a set. People wouldn't pay what it would cost for us to make any money. Not to mention the market size is so small that we would only sell 2 or 3 sets.

[@1fastbuggy502]

@@VintageVolks Hear you on that. If I can be so bold as to ask. Could I get a copy of the build spec's so that I could get them built for myself ? [e-mail]

[@VintageVolks]

There are no drawings. I just went out on a slow week with a couple pieces of 4340 round bar and a Sharpie to mark it all out. Then set it up on the lathe and turned/ground to fit.

[@KA4UPW]

Thats a big cut.. Wow

[@VintageVolks]

I don't remember if we did this case for 94mm pistons or 90.5/92mm, but they are standard sizes.