TheHaflinger.com

Can anyone/does anyone know an engineer who can rebuild a engine in Sydney, regards Danny

Danny - see my PM.

Also - a good VW mechanic might be able to point you in the right direction - maybe also a mechanic who specialises in older Fiats eg the 500.

Good luck

Garry

Thanks Gary, was leaning that way. thanks for the advice, re your pm. Danny

G,,day . they are fairly straight forward to do . a few little idiosyncrasies .
I am too slow typing to go through it all . but if you want to contact me I can give you a verbal .
I can also fax a bit that may help , have to find it first .

cheers ,
kerry

Thanks Kerry that would be great. I will contact you soon. Danny

Hi Guys, have seen a few comments around regarding Porsche cylinders and 84mm pistons. Has anyone on the forum done this/ or any advice. danny

I would assume that Porsche cylinders are much the same as VW ones when compared to the standard Haflinger barrel. That would mean having the crank cases bored in order to fit the bigger outside diameter of the barrel.
I think there is someone in the UK who has gone up to almost 850cc based on the original engine and fitting bigger barrels and pistons. Might make for fun and games with the cylinder heads - tops of the barrels and piston heads might need a bit of machining as well.

John

Vampyr wrote:Hi Guys, have seen a few comments around regarding Porsche cylinders and 84mm pistons. Has anyone on the forum done this/ or any advice. danny

I don't know about Porsche pistons and barrels but VW big bore kits will go in with as John mentioned a bit of machining. I have the 87mm barrels in my Haflinger - basically the crankcase needs work, the VW pistons need machining, the VW barrels need machining to fit the crankcase and heads, the heads may need a little machining depending on the way you wan to go - and if doing this work you will need bigger valves to make it all breathe.

The work needs to be done by someone who has done it before to work out what material needs to be removed or not moved - or at least have previous machined parts as a model.

87mm pistons give you 762cc so a lot more torque noting the the redline should not be moved higher without complete balance etc.

There is a 88mm big bore kit but the barrel walls are a bit thin and can cause issues - even the VW people steer clear of these.

Apparently the crank and conrods can be changed to increase capacity even further but I have only heard about this.

Oh - the VW kits only come in lots of four and the barrels and pistons are almost impossible to find individually.

Garry

Well have returned from Melbourne after a shopping spree for parts with Tony Hrelja, What a wealth of information, Now for the beginning of the rebuild. Will post photo's as the rebuild occurs.Danny

Have done most of the engine rebuild, quite fun actually. Must say it has been an adventure getting all the engine parts from around the world. Cylinders pistons and rings, push rods, con rods and distributor cap from Ebay de, from all different sellers. Bearings, clutch, crankshaft, seals, values and gaskets as well great advice from Tony in Melbourne. Not to mention he was a great help with new switches for the dash. Many other parts from other owners on the parts swap scheme. Another week or two and it should be in the haffy running, happy days. Danny

Just wanted to add a comment to those out there rebuilding an engine, my biggest concern was the right hand cylinder head. The head was in great condition bar the spark plug thread, it had been retapped, enlarged then a helicoil had been fitted incorrectly and there was no option of putting in an insert either.
I pursued the option of having the entire spark plug hole rewelded and then retapped. Well a year later still going great, no problems at all, very happy. Danny

Well I am very close to the assembly process on my rebuild. Other than the manual, I have very little to go on. Any tips?

Did you take the engine apart yourself?

The manual provides various technical specs but it is not the same as the well know Haynes manuals - It does provide some some basic instructions but on the whole it designed for people who have had some training on the Haflinger.

If you have taken any engine apart, you should be able to rebuild your engine.

John

Vampyr wrote:Well a year later still going great, no problems at all, very happy. Danny

Well Danny - you do know that as you have been bragging about this, you have now jinxed yourself and Mr Murphy is gonna make your engine fail next week and you will not have anyone to blame but yourself for being so cocky.

Good luck with that

Garry

heinkeljb wrote:Did you take the engine apart yourself?

The manual provides various technical specs but it is not the same as the well know Haynes manuals - It does provide some some basic instructions but on the whole it designed for people who have had some training on the Haflinger.

If you have taken any engine apart, you should be able to rebuild your engine.

John

Thanks John!

I did take it apart.

Take it one step at a time and ask questions if you are not sure on something that way you get it right first time and don't have to take it apart in order to sort something that was wrong.

John

Tony, one thing that I found quite difficult to do was to ensure the small raised "pin" on the casing sat correctly in to the cut out on the main bearing(s?) (1-05, #27, 501.1/2/3.01.088.1). This photo shows where I got it a bit wrong

Might it be ready by next month?

sit the bearings in the crankcase and lightly scribe some alignment marks .
then fit to crankshaft , then fit to crankcase .

not being smart . but i only did that once .
kerry

Well Gary, don't try and Jinx me, that's why I have a wife! The head was always my biggest concern and Murfy's law kicked in on the distributor. Now That its replaced I don't seem to have as many headaches, but thank the GODS its not a Landrover. Anyway thanks for the encouragement. Have cleaned the second engine and will take the heads off and look at the general condition. Have already done the carby. Regards danny

Thanks for the tips. I will definitely turn here if questions come up. I hope to have it done by the time you are here Julian. It would be fun to show you the neighborhood by Haflinger.