Great Job:

I would sugest adding headers from S&S and use  their muffler.
Davidb

EMZ wrote:

>    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
> >