Rebuild Snag

[n307tw]

Hey guys!

Started rebuilding my ultra low time Aerovee to convert it (at the factory’s recommendation) from a 2002 to a 2.1 so I can utilize the turbo. The bore measured good on the cylinders so I opted to throw new rings in and reuse them. Got most of my parts from Sonex or CB performance, no eBay parts here!! However, the new piston rings I received from CB Performance did not meet Sonex specs. My ring end gap ranged from .005” to .007”. Manual states the gap should range from .012” - .022”. Since I didn’t have a ring filer and didn’t trust myself to make a square end on the rings with a hand file I decided to take them to a local machine shop. My question is for you guys that rebuilt, did you ever have too tight of a gap for the rings? What did you do to fix it? Did you decide to go the machine shop route as well or am I being too obsessive compulsive?

[lakespookie]

I have built a few car engines but not a VW, Filing down the rings is ususally not a big deal. Like most things where you are removing material take your time and work your way to the size you need file a bit then check clearance again. Additionally since its a rebuild and you are using the same cylinders I would check the gap in multiple positions on the cylinder just to get warm fuzzies for the true of the cylinder. You should be more than familiar with deburring ;P.


Wiseco has a good blog post on the process http://blog.wiseco.com/how-to-file-fit- ... ston-rings

[Bryan Cotton]

I've always used a small file. Had to do a couple on the Aerovee, a couple on the Saturn, and a few more here and there over the years. No big deal.