Archive for February, 2008

Feb 24 2008

engine repair finished!

Published by admin under mechanical

I finally got back to working on the car the other day.

First, I rebuilt the injectors, which involved taking them all apart and cleaning them, and then some of the parts had to be resurfaced to a shine so they would fit together cleanly and not leak. Vince Waldon has the detailed process on his blog, and I pretty much followed his instructions. It took a lot longer than I had anticipated. After I got the parts cleaned and resurfaced and then cleaned again with acetone and brake cleaner, I reassembled them with brand new nozzles and installed them in the car.


injector parts


rebuilt injectors

It took a couple of sessions to get it running. This car had sat for three years before I bought it, and a year since then. I was pretty worried that the injection pump might have dried out and would leak all over the place when I tried to use it. I spent one evening getting the injectors in and all the belts and power steering pump and alternator and what not back on and then trying to get it to start up. About the time I finally got all the air out of the system, the battery ran down, so I put it on the charger and came back the next night. I had to fiddle with the timing a little and then it started right up like it had been running just yesterday.

It’s not perfect yet. There are a few little problems and for some reason it has eaten two alternator belts already, but soon I will have that ironed out and can start enjoying the 50 MPG that this car should be able to get.


completed engine

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Feb 17 2008

County Line Park to Skamokawa

Published by admin under kayaking

Today, I took the day off from bashing my knuckles working on the car and went kayaking. Originally, Karl and Andrew and I were going to go to Ilwaco, but Karl bowed out and so we went with a revised plan instead. Andrew’s old friend Neil came along and brought with him Annette and Jay. We started out at County Line Park, named for it’s being near the county line, of course. The plan was to paddle from here downriver to Skamokawa, about 16 miles away.

I took a ton of pictures, but most were pretty washed out from the bright sunny day, or blurred beyond use from water on the lens. Oh well. A couple of the blurry ones were kind of cool, so I kept them.


waves and splashes

We stopped on White’s Island, just upstream from Puget Island so that Andrew could check on the horned lark population that he has been monitoring there for years. They have not been so happy with all the new dredge spoils dumped on top of their nesting grounds by the Army Corps of Engineers, but if it weren’t for the Corps, there wouldn’t even be a White’s Island, so what can you do?

While Andrew and Jay went for a quick hike, I wandered on the beach looking at all the flotsam and jetsam, and I found more evidence that irony is alive and well.


irony

Zero garbage, indeed!

We stopped for lunch on this little beach, tucked away in a corner, and out of the east wind. This beach is covered with gravel deposits from the Missoula Floods, thousands of years ago. Andrew found several pieces of petrified wood while we were sitting there.


lunch

Now the outgoing tide was starting to pick up nicely and after lunch we practically flew along the basalt cliffs, past several waterfalls, to Cathlamet, where there are a number of boats of all kinds tied up at the old working waterfront. This craft appeared here a couple of years ago, and I had a Chinese couple on a tour that fall who translated the characters on the side and told me that they meant “Lucky Star”. She doesn’t look so lucky anymore, or maybe she is just lucky to still be afloat. She looks like an old longliner, and has such a pleasing shape.




number 37

We really lucked out on the weather, as it was sunny and almost warm at times, and what wind we had was at our backs. We got to Skamokawa a little before 4 PM, about 5 hours and 15 minutes from when we launched. A very nice day!


kayakers

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Feb 16 2008

VW repair-day 2

Published by admin under mechanical

OK, well it’s back to work on the broken Jetta. I just can’t afford to drive this truck everywhere I need to go! I went back to Portland a few days ago, and spent another pile of cash on more parts. Aren’t they purty?


hundreds of dollars

That’s about $720 sitting there!

Anyway, on to the task at hand. We left off with the head removed and marveling at the damage. The next job is to scrub the top of the block and the bolt holes clean, and get the head ready to install. Manifolds go back on now, and new glow plugs. Another task that you won’t find in the Bentley manual is peening the head around the pre combustion chambers. These little inserts are common to many indirect injection (IDI) diesel engines and have been known to work themselves loose and fall out of aluminum heads like this one. So a few strokes with a punch and a hammer are needed to deform the soft aluminum around the inserts and help keep them from coming loose. Careful not to peen where the sealing edge of the gasket sits! That’s what the little arcs in pen are for: to remind me of where that edge will be. Thanks to the guys at dieselvwparts forums for making me aware of this potential trouble spot.

Here’s a picture:


peened pre chambers

Make sure that none of the pistons are at the top of their stroke when you set the head down, so you don’t damage a valve. These diesel heads have next to no room to spare for a valve being open in the wrong place. After some futzing around and improvising to hold the gasket in place, I set the head down and started the bolts in finger tight to hold it in place. This is an awkward job if you are alone like I was. Careful of your back, that thing is heavy with the manifolds on. Next thing is to lightly oil the bolts around the washers, cross your fingers and torque the head to the Bentley manual specs. These are Torque to Yield (TTY) bolts and can only be tightened once.


head is on at last

At this point, I had to switch programs to deal with some tedious tasks: changing the water pump and the intermediate shaft seal. None of this part was very fun, and I was too distracted to remember to take any pix. I had to make a special tool to hold the IM shaft pulley while I removed the bolt. Here is version 2 of that tool; version 1 was partly made of flat stock instead of angle iron and it bent all to heck when I leaned into it. I sure love having a cutting torch around. I know this isn’t as pretty as one made with a bandsaw and a drill press would have been, but the torch is fast.


home made pulley tool

I lucked out on the water pump; often the bolts just break off in the aluminum housing, leaving you with a really annoying removal job or another trip to town for a new housing. Fortunately for me, someone had already changed the water pump once before, and all the bolts came out easily and without breaking.

So, at the end of the workday today, I have the head installed and torqued down, the water pump, thermostat and IM shaft seal all replaced with new ones, and I am ready to install the timing belt and rebuild the injectors. Stay tuned!

Tomorrow, though, is a kayaking day.

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Feb 10 2008

walk in the woods

Published by admin under forest, home

So, I tried to stay focused on the desk work today, but it was nice outside, not raining, and I finally gave it up and went out. Chopped some firewood, let the sheep out to play and then decided to go for a walk. I took a rifle and the dog, and set out to exercise my god-given rights as an American to go to my local clearcut and shoot at stuff. Well, that wasn’t really the purpose of the hike, or taking the rifle. I already had the rifle with me, because the coyote predation on my sheep has been so bad that I can’t let them out of their night pasture without first walking the perimeter with a firearm, doing some target practice and making a lot of noise so that the coyotes won’t want to come near. By the time I was done with that, I was at the top of the pasture at the forest gate with an unused clip of ammunition on my pocket, so I just kept on going up the hill.


sheep grazing

There is a logging road that cuts through a corner of my land, and heads east to dead end in a year-old clearcut about half a mile away. When they first came in that winter and started extending the road, I was in the middle of chanterelle picking season, and so I decided that I should go clean out the chanterelles up there before the equipment showed up and started wreaking havoc as they do. The unit that they cut is probably about 100 acres or so, and it was all plantation hemlock, about 50 years old. I spent half the day wandering around in that forest and didn’t find anything growing under that dark, crowded thicket. There were hardly any ferns even, and no mushrooms. I had just about given up, when I came out the other side of the unit and into naturally generated alder and cedar forest along the edge of a little canyon. And there were the chanterelles. They wanted nothing to do with that plantation hemlock, and instead were growing in abundance right along the unit boundary.

It took a very small number of men and machines a very short time to lay that forest down. The log truck traffic was non-stop, as was the litter the truck drivers dumped on my land while they were pulled off on one of my side roads waiting for the outgoing trucks to pass. I was very glad when it was over. Now it is replanted to fir, which is already showing fast growth.


clearcut

I hate what clearcutting does to the land and the water quality and I think monoculture makes a lousy substitute for a real forest. But for now, anyway, that is the way things are done, at least in my rural corner of SW Washington state. I have to find a way to live with this around me without being angry and sad all the time. So I take my walks and I look for the beauty where I can find it. The view of my valley from this spot is beautiful and I can look over the ridgetop and into the next valley from here as well. There were a number of birds including a couple of unidentified hawks in the distance as I came up into the opening. The elk and deer come through here too, eating the brush that is starting to grow up. There are a couple of huge maple trees at the edge of this cut that for some reason were left standing. Edges are nice.


me with rifle

The rifle I took with me today is a surplus Russian SKS carbine, made in 1951. It was cheap to buy 15 years ago or so when I bought it “new”, about $140 if I remember correctly. And it is sturdy and durable, cheap to shoot and pretty accurate for what it is. I picked up one of the ubiquitous beer cans and set it up next to a stump and then walked away until I could barely make it out, probably about 150 yards or so. I took six shots at it, and while none of them hit, they all were within a few inches, not bad for iron sights and not much practice. I was always told by shooting buddies many, many years ago that you should never expend all of your ammunition when shooting out on the back roads. “You never know what kind of trouble you might run into on the way out to the truck,” they would say. Seems a mite paranoid to me, but here I am, way out in back by myself, in bear and cougar territory, and having a way to make very loud noises might come in handy, so I left a few rounds in the magazine when I was done.


rifle

Speaking of beer cans, they are everywhere in a clearcut. Recycling is just not part of the program here. All the way out the road, there was at least one beer can every fifty feet or so, and there were probably a half dozen of these beer cans stuck on branches and shrubs. I guess the rednecks want to be sure everyone knows that they were there. Trust me, guys, we know.


beer can

The dog just goes crazy on these walks. For a while I stopped taking him because he would get off on some tangent and just disappear, showing up at the house hours later, all out of breath and covered with mud. Obviously great fun for him, but since I hate livestock chasing dogs, I don’t want mine to be one too. But today I had pity on him and took him along, and he mostly stayed within sight. Here he is, actually waiting at the gate, instead of going around. How well-behaved!


forest gate

Near the forest gate, at the edge of the pasture, is an old vine maple tree that is just covered in the lichen known as usnea longissima to the binomial Latin nomenclature types. People sometimes call it “old man’s beard” or “spanish moss” but it is not a moss. It is used medicinally as an anti-bacterial among other things.


usnea longissima

So there you have it, detailed instructions on how to get out of doing office work for a few hours! Helps if you have access to a dog, a rifle, a logging road and a clearcut full of beer cans, but I’m sure everyone can find their own appropriate substitutes nearby.

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Feb 09 2008

VW repair-day 1

Published by admin under mechanical

Well, after I towed home the green Jetta a while back, I looked it over and decided that it has so many things wrong with it, that it would be cheaper and faster to get my other Jetta going instead. The blue Jetta is an ‘89 diesel, with only about 135k miles on it, half the mileage that the green Jetta has. I got it for $300 off of Craigslist about a year ago, because it had a cracked head. The previous owner had installed new injectors, but he overtorqued them and cracked one of the injector wells. It also has some damage to the front fenders. For $300 though, it has all new shocks and almost new tires on nice factory VW spoked alloys. The interior is pretty clean, although not as plush as the green Jetta, which is a Carat, with the sunroof, power window and premium seats and upholstery. I’ve been wanting another diesel VW for a long time. Many years ago I had a couple of diesel VW Rabbits, and they were great cars that were very cheap to drive. So I was initially really excited when I dragged this one home.

I think I can get this one going for about $700-800 and a few days of work, and it should get mileage in the high 40s to low 50s if my previous diesel VWs are any example. And I will be able to burn biodiesel in it. I have been using that in my Cummins powered Dodge truck off and on for the last year. It runs great and smells nice, too!

The cracked injector well:


cracked injector well

I looked for a new head for this car for a awhile, after I was told that the crack could not be welded. Turns out that the model of diesel engine I have here was not a very common one, and finding another head was not easy. I finally found a brand new one on eBay, located in Vancouver, WA and miraculously, I won, even though I was away from the computer when it closed. I got run all the way up to my maximum bid, too. After picking up my prize, I headed over to Halsey Auto Parts in Portland and got the requisite gaskets and so forth. It took me a half a day to clear out a stall in my shop and get the car rolled in there. Today, I dove in.

Here it is, with the valve cover, timing cover and air filter removed:


day 1


day 1

After a while and a little struggle with stuck fasteners, I got the head off and cleaned up the block:


day 1

Then it was on to cleaning up the broken head, removing manifolds and other parts that will go on the new head. By the time I got done with that, I was starting to get a new shopping list together. Several of the fasteners that held the manifolds on did not survive removal, and the glow plugs spun in the head when I tried to pull them. I also got my first good look at the extent of the crack in the head. The guy actually over tightened TWO of the injectors, and the crack traveled all the way through the water jacket and through two injector wells. What a mess!


day 1

I would have just kept going and put the new head on today; I need this car to be running soon, but the messed up fasteners and glowplugs necessitate another trip to Halsey before I go on. Can’t do that until Monday or Tuesday, so tomorrow will be a desk day, catching up on all the office stuff I have been neglecting for the last couple of days.

Here’s the end of day 1:


end of day 1

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