i bunged it through the google translator...
(no pics sorry)
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Engine 800 at Fiat 126p
The following text is copied with the consent of the parties Deniora
http://strony.wp.pl/wp/tdoening A few words of introduction:
800ccm engine capacity is built block 650 Achieving such a high capacity on the same block entails a lot of modifications the same block and a piston-crankshaft system. So far this design is tested in two cars - Polo Deniora - and so far after covering 8.000km not shown any side effects. The advantage of this design compared to the total engine transplants is that absolutely nothing from the outside can not see, so you do not have cars przerejstrowywać greater capacity. If someone, after reading the following material were still doubts about the installation, let the questions will refer to Polo or Deniora.
What you need to buy:
1. two 86 mm pistons with rings and pins with the Beetle 1600 (as of today, 200 PLN)
2. two cylinders of the Beetle 1600 (a shallow head) of the heat sinks are not broken (I got used to the free perimeter of 85.5 mm)
You can buy in Cracow Mr. Andrzej Folty, st. Jasielska 14, tel (12) 267-35-85,
3. shaft with bisa (I mean fine counterbalance) the price depends on the source, rather a new way
4. Crankshafts with two sleeve beetle (after 2 PLN)
5. a piece of sheet copper gasket on the head with a thickness of 0.3 to 0.5 mm
Tools needed:
1. drill
2. leaves No 40 and 120 or subordinated (to the end of a drill with sanding sandpaper petals around the plastic core)
3. SAG
4. cutting disc
5. sanding disc
To block engine was more resistant to breakage have to strengthen, should rejoice at the block wall below the gallery, opening the pan from the shaft of the flywheel as a result of the cooling material is slightly distorted have to very carefully (so as not to overdo it) to scrub the pan and then check whether shaft rotates slightly as it is possible curvature of the acetabulum, and may not be in the shaft.
The next step is to prepare the cylinders, they must necessarily be a cylinder of "shallow head" they have a lower edge which comes into head Beetle (cylinder is treated less about 4mm from the serial and the cylinder head for the deep that were shorter by almost 1 cm) have bring the cylinders to roll grinder and has protruding from the top of the first rib rant slightly sinking them (only offset) so that it comprised an area of support head, first rib cut (a circle with a diameter of 10 cm) that did not break when tightening the head, then measure 79 , 5 mm from the surface of contact with the cylinder head to this place and grind the lower part of the cylinder so as to create a place of support for the block (height of the cylinder from where based on the block is 79.5 mm), it was unclear if something is drawing. In the case of not having a shallow cylinder head should be performed in the cylinder / g figure but subject to the dimensions of the bottom (OLAC podtaczaniem upper part of the ribs and head support to do on the collar of the cylinder).
When the cylinders are now ready to be with the angle grinder podszlifować all the ribs that interfere in the cylinder is inserted into the block between the cylinder clearance should be about 0.5 mm, then you must cut out the użebrowaniu slot pins. There is a possibility that the play (or lack thereof) between the cylinder and the crankshaft counterweight is too small (should be at least 2 mm), in which case you must cut out the cylinders and pistons suitable undercuts for retaining the symmetry of the pistons (undercutting of the two sides symmetrical piston), all smooth out the edges nicely.
Then prepare a set of piston crank, you need to bring rods into grinders that settled from the bushes and rozwiercił beetle (tightly fold) to the piston pins Beetle (diameter 22 mm - standard tube is 20 mm), standard rods are accurately finished and can be removed unnecessarily large part of their material which will reduce the weight (standard piston crank sets are lighter by about 2x100g from a set of 800 grams lighter each wound brings us to a better balancing of the crankshaft, which reduces the risk of rupture of the shaft) and after wypolerowaniu increase fatigue resistance, it should be polished and then polish with such endings Drill lobe "according to the figure below. The entire balance as accurately as possible (the two sets must weigh exactly the same, it is helpful kitchen electronic scales)
As already crank piston system will be installed in the block will be able to take the head. The head should be zaspawać screw holes for drainage gas leaks and grooves, offset by a weld head, and then planning to expand the dimension of the combustion chamber of the cylinder (~ 86 mm), is to reduce the degree of compression to choose some material from the bite, but do with the measure the capacity of the chamber (syringe and how much water enters the "flat"), we calculate the compression ratio = volume of the combustion chamber + 408 cm3 / combustion chamber volume (you should not exceed 10.6 and the maximum 12, then you have to pour a very high octane fuel).
We need a gasket, cut the copper plaque thickness 0.3 - 0.5 mm. If the plunger is slightly protruded over the cylinder (can happen if the height of the cylinder is less than 79.5 mm) it must be done properly thicker gasket. The diameter of the hole in the gasket should be slightly larger than the diameter of the piston in the cylinder so it does not impinge openings dopiłowywać best for a particular system seals (do stamp) because the reversal can not agree.
The engine warms up more than just baby oil temperature may reach 150 degrees so it is advisable to use additional cooling oil, you can use an aluminum pan with a capacity of 4l (the temperature drops about 20 degrees) or the oil cooler.
It should also establish a long box (from the Bisa) in order to make better use of a more powerful engine on the route or leave the merge which is a bit too short for the engine but good for tight KJS'ów.
The burning of the city around 7-8l route when driving around 80 km / h 5l.
At the end of the characteristics of the engine was completely serial fields in addition to increased capacity and lightweight flywheel. As you can see the pits but it is very fast with the roller can be nicely compensated. When using a roller 385 is similar to the characteristics of the series, ie max torque at around 3.5 thousand, very pleasant to ride.
