Ran the heads through the ultrasonic. Had to put the valve keepers in a press to get them to pop. Gotta say, never had to do that before - but this motor has been a long time sitting. Valves cleaned up nicely, valve tips looked like this:


Couldn't catch a finger on it, but still peace of mind wanted them cleaned up. My local VW hot rod shop chucked them into the grinder, and in under a few minutes cleaned them all up up (only 2 of 4 shown of course).

The kicker, he said "have a great holiday" and sent me home f.o.c.! Refused to take any payment despite my insistence. Love old school places who like doing old school stuff. Gotta figure out how to keep them in business.
Started the cylinder build up - and let me just say - when the Italians say "everything is pre-sized", what they MEANT to say is they INTEND for everything to be pre-sized. After putting one cylinder and head together, torqed it up - engine was pretty tight with only one cylinder installed and that was not a good sign. Pulled it back apart, and found the oil control ring gap to be 0.0025". That's not going to work.


Now we check them all. Luckily, no wall scoring and this should be better once I get it back together again. Thankfully I've got a spare head gasket.