So the butcher has a 1.8 stroker on the back burner. Eventually the engine will be going in my wife's Cabriolet along with small boost turbo set up.
I've been collecting parts for some time and I've researched this intermediate shaft issue even longer. There are a few options out there but I did not like any of them. Although shaving the gear,, so it will miss #4 rod is the go to method on the stock 1.8 block, I've just have issues with the shaved gear and longevity. I understand, no one has had an issue, and I'm concerned about nothing.
I decided to slightly press the gear off the shaft and check to see if the distributor gear is still aligned. I have found it you move the gear just over 2mm, that will allow enough clearance for the rod to pass without any damage. The distributor gear alignment seems to be ok too. What I plan on doing is drilling the end of the shaft and tapping it to accept a bolt. I will make a 2mm shim and then press the gear back on. Once it's completed, I will install the bolt and large washer to keep things from coming loose. There is plenty of room for hardware to keep the gear attached.
It's in the mock up stage and ready to go back into the corner of the shop. I hope to have the engine completely disassembled so I can get the block bored next week. The way I do things, it will probably be 15 years before I finish this project. I seriously need to get back on the POS.
This is what the shaft looks like installed
The distributor gear alignment
And the shaft out of the block for a better look.
Anyway, more useless information for those that want 2 litres but do not want to go the ABA route.
I've been collecting parts for some time and I've researched this intermediate shaft issue even longer. There are a few options out there but I did not like any of them. Although shaving the gear,, so it will miss #4 rod is the go to method on the stock 1.8 block, I've just have issues with the shaved gear and longevity. I understand, no one has had an issue, and I'm concerned about nothing.
I decided to slightly press the gear off the shaft and check to see if the distributor gear is still aligned. I have found it you move the gear just over 2mm, that will allow enough clearance for the rod to pass without any damage. The distributor gear alignment seems to be ok too. What I plan on doing is drilling the end of the shaft and tapping it to accept a bolt. I will make a 2mm shim and then press the gear back on. Once it's completed, I will install the bolt and large washer to keep things from coming loose. There is plenty of room for hardware to keep the gear attached.
It's in the mock up stage and ready to go back into the corner of the shop. I hope to have the engine completely disassembled so I can get the block bored next week. The way I do things, it will probably be 15 years before I finish this project. I seriously need to get back on the POS.
This is what the shaft looks like installed
The distributor gear alignment
And the shaft out of the block for a better look.
Anyway, more useless information for those that want 2 litres but do not want to go the ABA route.