Piston Q

[jdbubb at verizon.net (Dan Bubb)]

Well, technically the piston should have a shorter pin height, by half the difference in stroke between the TDI crank and the 2.0L crank, 1.35mm I think.
IIRC the ABA steel head gasket is 1.65mm thick compressed. So, two of them stacked would give you about 3.3mm or 1.3mm above your piston which is just about the right piston to head clearance.
I don't know if that's a good solution though. I'd wonder how well they would seal if the embossing on the two gaskets didn't line up close enough.
If you go with a copper gasket measure the piston protrusion from the block using a micrometer or caliper. Add .040"minimum to that for the final gasket thickness.

As a minimum, after you modify the pistons for oil squirter clearance, you need to get them rebalanced. You can modify them yourself, but I'd be striving for an identical cutout in all the pistons.
Dan

From: <marc_scirocco@xxxxxxxxxxxx>
To: <scirocco-l@xxxxxxxxxxxx>
Sent: Monday, May 07, 2007 8:47 AM
Subject: Piston Q


>I installed my TDI crankshaft in my 9a block this week-end hoping to get 2.1l of 8v power ;-)
> 
> The crankshaft spins freely without hitting anything, so that is good.
> 
> However, there are two snags as I see it.
> 
> 1. the piston stick about 2mm out of the cylinder at TDC.
> Can I safely run 2 head gaskets to bypass this problem?
> I have seen a shop in the norteast that can make me a copper head gasket, Perhaps this can be a more permanent solution in the long term.
> 
> 2. on the bottom stroke, the piston hit the oil squirter.
> There is already a notch in the piston skirt for the oil squirter. But I need a bigger notch.
> Do I need a machine shop to do it or can I just enlarge the notch at home with my die grinder?
> 
> Thanks
> 
> Marc
> 
> 
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