I haven't even had my first cup of coffee yet, opened up this thread, my, my, my, what a beautiful project! And to still be going at 72 with a complete rebuild of this magnitude. What lovely Man Cave Project. Simply a wonderful thread, well done!
My last motor build was an Audi 5000TD 5 banger motor. 1991
My most expensive rebuild was a stroker 2180 out of my 1500 in my 1967 VW Beetle with factory sunroof.
BTW, my new 2014 Passat TDI has 22 k miles on it, and the coolant is brown as can be, not pink G-12... VW is having problems with casting residue too, and it clogs up the heater core ( full dash removal for that one) the EGR, and the water pump/ thermostat. Poor quality control on a little diesel motor made in Poland by VW. They never learn.
We will see what VW's solution is to the gunk in my coolant system, as a flush probably won't be adequate.