Any engine builders? Newbie with questions...

[mrsimpson]

Hi,

The girlfriend has given me permission to build an engine in the spare bedroom. I've no idea what I'm doing I've bought a few books, and now I'm after a new crankcase...

What am I doing? What am I looking for? ANY help would be great, I've seen there are aluminium and magnesium cases, I understand that the aluminium one is stronger but heavier, but I've also noticed a few different brands.

I'm looking to build a mildly modified engine, something that will pull a bit but be reliable enough for the occasional european tour.

:mrgreen:

 

[ianscooby]

Hi,

The girlfriend has given me permission to build an engine in the spare bedroom. I've no idea what I'm doing I've bought a few books, and now I'm after a new crankcase...

What am I doing? What am I looking for? ANY help would be great, I've seen there are aluminium and magnesium cases, I understand that the aluminium one is stronger but heavier, but I've also noticed a few different brands.

I'm looking to build a mildly modified engine, something that will pull a bit but be reliable enough for the occasional european tour.

:mrgreen:

You want an AS41 casing, I can reccomend someone that has just built my 1776.

 

[Justin & Muttley]

Don't forget, that baby will will be heavy when it's finished and you're going to have to carry it downstairs!!! :lol:

Best of luck with the build, get a thread going...

 

[mcvw]

I think I'd be tempted to go for a 2007 (I've got a superb 1776 lined up for our bus. It pulled like train in our old bug - though I think it may be revvy for a bus).

 

[VeeDubMan]

I was in the same position as you a few years back and found this book to be excellent: How to rebuild your Volkswagen Aircooled Engine http://www.amazon.co.uk/Rebuild-Your-Volkswagen-Air-cooled-Engine/dp/0895862255. I ended up building a 1776cc with twin 40 Dellorto's, Engle 120 cam etc. Put out about 100bhp in the end but used it in a bug. In a van though go for something like an Engle 100.

Be warned, building even slightly modified engines is not cheap. And don't cut corners. I got a second hand AS41 case, got it bored out to 90.5mm for the 1776cc pistons, align-bored, full-flowed...put it all together and then found out there was a hair-line crack in the case which weeped oil. Had to scrap the case and start again and vowed never to buy second hand again.

Good luck.

 

[mrsimpson]

Thanks for the advice and support, I'll definitely make a thread of the build.

Weight, I was worried about this, too heavy for me and a mate to carry downstairs?

I've got that book, and I was talking to someone at volksworld who said that the DVD's of engine builds are great. I did find a few on youtube also that were very useful.

Right I'm going to purchase an engine stand today!

 

[Justin & Muttley]

...Weight, I was worried about this, too heavy for me and a mate to carry downstairs?...

Not too heavy for two of you to carry downstairs (unless you both look like the Mr. Muscle guy), I'd just be worried because carrying any large item (bigger than a suitcase) upstairs/downstairs in our house leads to much giggling/hilarity!!!

 

[Araon]

Buy a sledge and let it ride down....

I have to admit I wouldnt be building it upstairs, **** man the poor guy on the lower treads is in for a frightening job.....

 

[james_stan]

Hi there

Built one a couple of years ago in my cellar. really narrow stairs but got it out OK with a mate.
Leave teh fan-shroud etc off and that will help..

WRT the engine, then clearly a new case is ideal. Less cleaning, measuring assessing for damage etc.. HOWEVER, taking an old engine apart is good experience in itself - best not to do this ithe bedroom though through fesr of retribution due to oil spills, cans of Jizer etc..

Things I recall from the build..

If re-using old parts get some TAPs and dies for cleaning threads.

Any aftermarket cam will require some setting-up of valve geometry (loads on thesamba about this)

Make sure any case you get has the rear mounting holes for the support bar
(mine didn't).

Get case 'full-flowed' for external filter.

Take care fitting the dissy drive - a pain and easy to lock-up engine.

If you get a lock-up - try torquing engine halves without cam fitted.

Buy or make a deck-height checking gauge.

Bigger barrells will need case 'spot-facing'

Don't be worried if new bores (I had 90.5s for a 1776) encroach on you case-savers - notthing to worry about apparently.

Buy the Tom Wilson book as mentioned and join thesamba and check out the performance/engine section.

Any questions ask away. I'm guessing that quite a few have done this at least once (or only once in my case..)

Cheers

James