Other than the high life rockers, I have done most of this to
my 2 Wheel drive Vanagon. IT FEW!   Your on the right track!
REmove the Cat and adjust the timing. NO need for a SWAP!

            Eric                   86-VW4x4
            vw4x4@fyi.net          72-240z
            Pittsburgh, PA USA     1936-Chrysler
   

On Thu, 8 Oct 1998, Robert Lilley wrote:

> To those that want to have more power, but do not want to do a engine swap, but are in need of a rebuild soon...
> 
> I am in the process of rebuilding my 88 2.1L Wasserboxer.
> 
> I had planned to only do a head gasket repair, but with the death of my transaxle I have decided to do a full engine rebuild with some improvements.
> 
> Here are the improvements:
> 
>  1) Full engine balance- all rotating parts as a unit.
>  2) Match port the intake runners to the intake opening.(The runners ID was about 2mm smaller than the intake opening ID- to improve flow)
>  3) Clean up the welding on the exhaust system flanges at the head (My new exhaust had welds that restricted flow).
>  4) Matched port the exhaust elbow and the twin pipe inlets. (My ports were off center about 5mm off on one side of port)
> 
>  5) CB Performance solid rocker arms.
>  6) CB performance 9mm Rhino rocker swivel feet. (Stock are 10mm but not swiveled)
> (The feet are the same as 911�s and keep the valve stem guide wear down when increasing the lift)
>  7) CB Performance 1.25 Ratio rockers.
>  8) CB Performance cut to fit HP push rods- (to avoid having to shim the rockers
> 
> *The 1.25 rockers are the same as FGA is selling.  They cost under @$150 from CB Performance.
> 
> I am using cut to fit push rods to eliminate the need for spacers under the rockers and maintain correct geometry.
> 
> 
> 9) CB Performance Copper 1.5" exhaust gaskets
> 10) Chip upgrade
> 11) Bosch triple electrode plugs
> 12) Mild porting on Cylinder heads- to clean up rough casting, match all ports to same size
> 13). K&N Air Filter
> 14) Off set grind crank 2mm
> 15) LIFETIME warranty Super Turbo muffler ($58)
> 16) Rebuild heads with combustion chamber re-shaping to improve flow.
> 17) Sanded smooth throttle body casting roughness
> 18) Have the sealing surface of the head anodized to keep from pitting out
> (I have to do more research to see if it is possible and if it will really work)
> 
> 
> All of the parts used in the rebuild will be
> 1. German (except where none exist)
> 2. Cleaned 4 times, they will be polished to remove all traces of any foreign matter.
> 
> *I have done all the porting/sanding/grinding with my B&D Wizard (I wish I had one on my previous engine rebuilds)
> A tool like this is handy.
> I will be done in about 6 weeks, I�ll keep those interested with up dates
> 
> VWVanman
> 
> 
> Free web-based email, Forever, From anywhere!
> http://www.mailexcite.com
>