Deck height question????

[Special K]

I was checking the deck height before putting the engine together for good, and the "How to rebuild VW engines" book referenced .055" to .065" as optimum. Well I've got like "ZIP" for clearance, the piston is almost flush with the top of the cylinder on all four (at least they're consistant).

Now, I had the heads rebuilt, and they had to fly cut them .040", and gave me barrel shims to make up the difference. I should definitely be checking the deck height "without" the barrel shims in place, right? If that is the case, then could I just get thicker barrel shims to attain the correct height (i.e.- .090"- .040"[flycut]= .050" deck height), or am I going about this all wrong?

What could be the possible cause of this lack of clearance?

[Special K]

Oh, I forgot to mention, the engine came out of a autocross car that had zero miles. The P.O. left it out in the rain, and water went down the stacks. He hadn't realized this and tried to start the car, and bent a push-rod. The engine sat for two years before I got it, and the cylinders were shot (rust), but everything else was fine. The new Piston/cylinder set is stock dished 2.0L type, and it doesn't appear that the case has been worked at all, but then again I'm no expert. I'm kind of leary about assembling the engine with this deck height.....HEEEELLLPPP!!

[rmcelroy]

I to am trying to find out about deck height considerations.
I have a set of 1.8L heads coming and
I'm looking at using 2.0 crank/rods with KB 96mm flattops for 1.8's. I've learned that there is 10cc difference in the combustion chambers of the 1.8's and 2.0's heads. Should I get 96's for 2.0 instead?

"extra money" the oxymoron.

[SteveStromberg]

2.0 stroke needs 2.0 pistons as the 1.8 piston are "taller".Steve