[Vwdiesel] Help - messed in the head...

James Hansen jhsg at sasktel.net
Fri Apr 15 01:55:05 EDT 2005

You can put an insert in from another head, but why in the hell were they
machining it in the first place? Nothing has happened to it that should have
warped it, right?... or was it bad before and they sluffed it off the first
time through the gate?  Gotta have a really really good reason for cutting a
VW head other than "that was how it is done".  You want to know what the
warpage was across the head, what the measurements actually were.  Five
bucks sez there aren't any written down anywhere.

Lines...wrong cutting tool insert, too high a feed rate, too deep a cut.
CBN insert should have been used.  Either that or too much cut on one pass,
and the steel loads up the cutting edge, or worse fractures the utra-hard
edge, and leaves lines.  CBN can cut the head to finish like a mirror with a
slow feed regardless of the materials on the head. Out of the fry pan and
into the fire. Grrreat...  Last pass on an alum/steel surface should be just
enough to remove all the frog hair that grew there between cuts. Another
fiver sez it was cut in one pass.

Painted the head... sigh....  nice to hear rattle can overhauls are still
available. Sucks to have one done when you expect a REAL overhaul.
Does it look like the valves were at all changed, or did they machine the
head with them in too?
I know it's easy to criticize someone else's work, but sheesh...

-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com]On
Behalf Of Shawn Wright
Sent: Thursday, April 14, 2005 7:58 PM
To: vwdiesel at vwfans.com; diesel-Vanagon at yahoogroups.com
Subject: [Vwdiesel] Help - messed in the head...

Today I went to pick up the head I dropped off at JB precision last week for
a valve grind, resurfacing, new guides, etc. First thing I noticed was they
had *painted* the head! And it wasn't even a decent job, it looked like grey
primer! Next, I noticed the surface wasn't very smooth - I could see arcs
from the cutting tool sweeping across the surface every 1mm or so. In a
few spots, it appears a piece of harder material (probably from the pre-
chamber inserts) had dragged across and left a groove in the head.
The machine shop was closed, so I was unable to speak to the guy who
worked on it. I left it there and said I'd call in the morning.

In addition to the two things I think they messed up on, I also noticed a
hairline crack on one of the pre-chamber inserts about 1/4" long - should I
worry about this?

I am going to ask if they can strip the paint off, and smooth the surface -
am worried it will not seal well with the lines left from the cutter. The
head I
saw at the other shop I visited was like a smooth mirror finish - that's
what I
was expecting.

Any advice on how to proceed is appreciated. ThanksShawn Wright
'85 Jetta D
'88 Westy 2.1L, soon to be 1.6TD 5 speed
 (see progress at http://members.shaw.ca/vwdiesels)
'82 Diesel Westy

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