Case
They are first hot tank, then thoroughly washed by hand. The cylinder base area is decked and surfaced on a Bridgeport Mill to set initial deck height alignment between all four cylinders and and to eliminate oil leads at the base of the cylinders. Case inserts or “Case Savers” are installed, Align Boring and all remaining machine work is done and then the case is thoroughly cleaned again and painted.
Rebuilt Heads
JCS buys thousands of head cores every year. A good portion of those are scrapped for the aluminum “scrap value” because they are too worn to be rebuilt or require too much work. We select only the best cores for rebuilding to insure a high quality, dependable finished product and to minimize the amount of labor put into rebuilding a head. These select cores are then fully machined… valve guides are replaced with manganese-bronze guides designed for extreme wear resistance and improved lubrication. All valve seats are replaced with heat treated chromoly steel seats that promote a quick, high heat transfer rate from the valve to the cylinder head casting.
New Piston & Cylinder Set
VW Connecting Rods
Late style 1600 rod cores are shot-peened, sandblasted and checked for straightness. New wrist pin bushings are installed then rods are bored and honed center to center.
VW Crankshafts
JCS uses only 1600cc style “crossdrilled” crankshafts for it’s superior oiling properties. Cores are shot peened, sand blasted, then carefully inspected for cracks, straightness and damage to the dowel pin holes and threaded ends. Cranks are reground to exact specifications, micro-polished and a thread chaser run on both ends.
VW Flywheels
Only German flywheel cores are first inspected for worn or damaged teeth, dowel pin holes and clutch disc mating surface wear to make sure it has not been worn or cut too deep. After shot peening and sandblasting the seal area is polished, the dowel pin hole area is faced to ensure proper mating to the crank and then precision ground and polished to exact specifications.