With bodies all apart...I zinc plated all the tubes, screws and springs ...bead blasted the bodies and buffed them out with 000 steel wool...and powder coated the levers.
The only thing left is to replace the screws holding the butterflies to the shafts.
I ordered the 4mm screws from McM Carr...but am not totally happy with them. The heads are not just too big at 7,5 mm but the head angle is wrong at 90 degrees. When compared to the originals....the angle should be more like 55-60 degrees....I'll mull over these for a bit to see if a better option is available.
Here's the McMCarr screw on the right w/90 degree x 7.5mm wide head...compare to the OE screw on the left w/55-60 degree x 6mm wide head. Does anyone know the closest DIN spec for the OE screw? It might be 964 but I'd like to pin it down exactly.....with the hope of sourcing the correct one.
The slot in that new screw looks really deep. I would be afraid of breakage if it is torqued too much. Why not polish the original ones and re-use?
The OE ones are also very easy to break off the edges since those not being very deep ...there is less material engaged with the tip of the screw driver....happened to me on a couple of the screws. To remove the screws I had to drill out the end of the screw that was flared out making them all shorter than what I'd like to see. With new screws I was going to flare out the ends....I know some folks are going with Loctite only....so I might have to do the same...unless by some luck I can find the correct ones.
I can tell you really like that!....well me too. Now back to completing the engine.....I finished installation of the cylinder head and a new timing chain. I removed that water pump fan spacer that came with the car after some of you pointed out that it was required only with the aircon installation and sure enough, after I checked some photos of the engine during the teardown phase....I noted that the crankshaft had a double pulley (also the aircon version). I installed the correct single style pulley from a spare engine.