AeroVee 2.1 kit assembly

[mdavidow]

I would like to contact anyone who is assembling an AeroVee engine kit or who has recently done so.
I have some questions regarding special machine work required.

madavidow@gmail.com

[Gripdana]

I built my Aerovee 2.1 2 years ago. I did not do any machining. I simply followed the assembly manual. I haven't worked on a VW engine for 35 years and never built an engine. I have 92 hours on the engine and it has run as advertised. My motto for the entire build was "KISS" (keep it simple) and to keep it to the plans.

[Sonerai13]

I would like to contact anyone who is assembling an AeroVee engine kit or who has recently done so.
I have some questions regarding special machine work required.

Any required machining is already done when you receive your AeroVee engine kit. No machining is required by the builder.

[n502pd]

I just finished my engine build and hope to install it this week. With that said, all above (below?) answers are very correct. However, I had to shorten several head thru bolts to keep from interfeering with rocker shafts, and from interfeering with intake manafolds. I did do one thing that is extra; I installed Threadsert spark plug threaded inserts in all 8 plug holes. No problems encountered with that; just follow directions with the kit. PM if more needed. :)

[mike.smith]

I just finished my engine build and hope to install it this week. With that said, all above (below?) answers are very correct. However, I had to shorten several head thru bolts to keep from interfeering with rocker shafts, and from interfeering with intake manifolds.

I think that is the case for everyone. Hint: make sure you cut them down before you torque down the heads. I happily torqued my heads and then when I went to put on the rocker assembly I found I had to do a LOT of cutting. Test fit, cut, test fit, cut again if needed. Keep the flying metal out of your engine. Other than that there is no machining needed.

[sonexsteve]

I've run into a problem that may require machining, unless someone out in sonexworld or Tech support can come up with a solution.....my wrist pin connecting piston 3 to con rod 3 won't go through the con rod hole fully. It fits fine, indeed very well, in the piston holes, but will only slide into the conrod hole until the leading edge of the pin reaches the far exit from the hole when inserted from engine rear, then jams. Trying to insert it from engine front results in slight engagement, then jamming. I've liberally lubricated with lithium grease. Any ideas please?

[Onex107]

Very unusual. Look closely at the edge of the wristpin bushing on the front side. It probably has been hit putting a small upset on the edge. You can safely remove that yourself.

[n502pd]

I had the same problem, but I can not remember which cylinder it was on. I just took a patch of scotch bright and carefully, sort of spun it by hand several times to just allow the pin to be inserted. I agree with Onex 107 completely. Just dont over do it. :)

[Sonerai13]

I just took a patch of scotch bright and carefully, sort of spun it by hand several times to just allow the pin to be inserted

I've done the same thing a few times. It usually only takes a few swipes with the scotchbrite. Just go a couple of rounds and check the wrist pin. If you need more, just take a couple more rounds and check again.

You want to be able to push the wrist pin through with hand effort only. If you have to drive it through with a plastic hammer, it's too tight.