Last Parts

Today I have the final parts for finishing this engine: a oil drain plug, an oil filter, and a new vacuum pump.  I could not find a used pump that was not bow-tied.  A new pump was $244 US.  Import duty was $43 CDN.  That’s a lot of money for a part that you really do not need.  Vacuum pumps are used to run the brakes on VW cars.  But with no need for brakes on a boat, the part serves to connect the drive shaft to the intermediate shaft, and runs the oil pump.  I’m glad it’s here and a new part is actually best for a rebuilt engine.  Why put a used part on a new engine?




1.6 L Diesel As Of This Week

Two parts are left to buy.  I need a drain plug for the oil pan and the drive for the oil pump intermediate shaft/vacuum pump is pounded out.  Being a boat motor the vacuum is not needed.  I’m looking into the possibility of having the gear without the vacuum…





1989 1.6 L Model D (ME), 54 HP VW Diesel

Some time in 2006 I was struck by the notion of building a boat…a boat that was capable of   shipping some bigger water up here…a boat that was roomy enough to sleep several people…a boat that was truly sea worthy.  So following some research and later that year I bought the plans for a 22′ working lobster boat…a Down Easter…a Cape Islander.  It can be extended to 24′.

The need for an engine arose.  An inboard was what plans were structured.  So I began my enquiries.  It seemed that a small diesel would be best.  Engines from China and India were available, and inexpensive.  But there were tales that they were not reliable, too.  After much reading and searching I found that smaller VW diesel engines could be converted to this use.  Small, powerful, reliable German engineering.  I put the word out and soon had a local contact.  His children had run his 1989 Jetta into a tree on his farm.  He owned an identical vehicle and wanted to keep the body, but did not want the engine.  So one hot, dusty day I hauled the car home and parked it.  It sat in my hay shed…I don’t recall how long.  I paid $100 CDN for it…


And then I got around to hauling it out and pulling the engine during the spring of 2008, and I dragged the body back to its owner…


I bought the engine manual for it on EBay…


…and I hauled the motor from my enclosed shed to inside our house in the fall of 2008…


I began to evaluate it as I took it apart, cleaning the engine as I went…marking the pieces and placing them in separate, labelled ziplock bags that were then stored in dedicated plastic bins…

This is what cleaning would do…












I brought the head in to an excellent machine shop in my area for evaluation.  It was worn and needed replacing – $1K.  In order to make the engine as reliable as possible I decided to replace the oil pump, have the fuel pump rebuilt – $800, install new glow plugs, wiring, and tubing.  I paid as I went…scraping the money together a bit at a time.

I cleaned the block, and repainted it with engine enamel and brought it and the parts into the shop for evaluation.




I ordered a water-cooled exhaust manifold from England ($1K).  When it arrived it needed to be machined to fit properly.  The block was machined and rebored…

In the reassembly a part was missing…the bracket that attaches the fuel pump to the engine block.  I ordered the part and delivered it to the shop when it arrived…




A Simple Bracket


I don’t know where this bracket for mounting the fuel injection pump could have gone, but it’s not there.  And without it I cannot finish up the engine for this boat.  It was undoubtedly in the back of my shed.  But I have a feeling that it did not fit into the containers with all the other parts, and as of two months ago all those lose parts were taken outside to my metal pile in the bush in order to clear a place for building a new shop.  So yesterday I located one in the USA and today I will order it and have it shipped here and then the engine rebuild will be complete.  It’s about time, and I cannot wait…

Lead Line

Smelting lead and pouring ingots…

Filled with molten lead this copper pipe has smooth sides and will not corrode.  It’s small diametre will produce little drag.  It is a good, inexpensive device for sounding…


A Pictorial Record Of Building A Glen-L Eagle