Well, I have now finished the re-build of my VW. It is now a 2276 running 8.5 to 1 compression. I hope to finish the installation today or tomorrow. I did run into a little issue right at the end that some of you VW people may have had to deal with and can shed some light on what needs to be done about it.
After I torqued the prop hub bolt to 80# as stated in the GPASC manual for the force one hub, the holes in the bolt head did not line up with the holes in the hub, for the cotter key. I checked the manual and it says to "sand" the washer down a little to get it to torque to the right place. OK, so, having access to a milling machine and knowing that sanding on a piece of metal that hard, would only end up in bloody fingers, I took 2/1000 off the washer and torqued it again, only to have gained a very little. I needed to get it turned around, one full "flat" on the bolt head, to get to where the hole is. So I did a rough calculation and figured that I would have to end up taking 9.8/1000 off the washer to get it to where it needed to be, and then if I screwed up and took off too much, then it would be another, almost 10/1000 to get it to the next flat, which would not have a hole in it anyway. The point of all this rambling, is to say that this seems to be an impossible task, which is why no one puts a cotter pin in a nut that has to be torqued. Either you need to back off the 80#, which would leave you with a sloppy fit, or torque way more than 80# which would most likely break the hub and still not get you there. Not being able to come up with an answer, I just put on some Locktite, and torqued it back to 80#. What have you other VW people, and I know you are still out there, done when faced with this problem. I can't believe that no one has seen the problem, because the chances of its being right on, are very slim. My understanding of the purpose of this cotter pin, is to keep the bolt from backing out, so why then, was it not made with reverse thread. That is what I was instructed to do on my first VW engine, which was not a "force one" hub, and it worked just fine. Daniel R. Heath da...@windstream.net See N64KR at <http://krbuilder.org/> http://KRBuilder.org - Then click on the pics
