Hi all,
Firstly this is not going to be a full on engine build thread with everything written or photographed as there is lots of those type threads already on the internet if you do a search. It's more a quick overview of the process with photos telling most of the story.
Link here to previous parts that arrived since last year.
Quick list of recent main parts (Supplied by Rod Penrose) :
CB Performance Aluminium Case
Pauter Roller Rockers
Scat Wedge mated Crank, Flywheel and Gland nut
Scat 'H' Beam Rod
Scat Chromoly Head Studs
AA 92mm thick wall cylinders
AA Forged (really) pistons to suit
CB Mini Wedge Port heads
Engle TCS 20 cam and Followers
Most of the fuel injection stuff is from the 'VW Speed Shop' in Great Britian. ECU, wiring, coils and sensors from the USA.
This long process started around November 2013 when I pulled the motor out of my car that I had intended to convert to turbo, injected etc. After pulling the engine down and inspecting, it did not have the internals that I was told it had when I purchased it as a completed running motor. The parts were good for what it was, but not for what I am planning on doing. I then had months to wait for some of my parts to arrive from the good old US of A.
This is just a mock up of the Turbo exhaust to see how it fits and to make sure the Turbo was going to clear my rear valance before I pulled old motor out.
Parts finally arrived and the long preparation process of blueprinting the engine begins.
The engine case havles themselves need modifications. The oil pump pickup hole is misaligned and as were the main journal oil supply holes. The black texta lines are indicating where the actual bearing oil groove lies. Both needed porting to match up.
A modification to the Cam followers allowing more oil to pass through and up to the rocker gear. This aids in lubrication, but also aids in increased cooling of the heads.
The camshaft needs to be clearanced in 8 positions to stop the conrod big ends hitting it due to larger crank stroke.
Camshaft bolts also need clearancing to make sure they dont kiss the oil pump.
Checking the cam lift to make sure it is the same as the supplied information card.
Bolted top half of case on and checked cam shaft and crank shaft end floats. And about to check deck height to see what I have to start with. Obviously way to much, but needed to work out how much material I need to remove to obtain the desired compression (deck height).
Then time for cleanup so as the assembly process can begin.
Although this doesn't show a time line, there is a lot of work involved to getting the engine case and components to this stage. This actually took me weeks to here as only working on it here and there. Beginning of the assembly process. Also as going full flow from the oil pump, need to fit threaded plugs into case and oil pump.
Case halves finally together, oil pump fitted.
Then started fitting a few of the external accessories. Deep sump, oil cooler adaptor, crank angle sensor parts.
Added an extra external oil cooler to the car.
Checking ring clearance and adjusting to suit. Case savers and barrels (no pistons) fitted to engine case as mockup to check head stud bolt lengths.
As you can see here, the head bolts are to long and all need to be shortened.
All rings fitted back onto pistons and pistons fitted into barrels. Then barrels and pistons fitted to engine.
As of today, heads now bolted on for last time with new pushrod tubes and seals.
Just sat rockers on quickly to see how they look and I love it.
As I said, this engine build process has taken me about 2 months working on it when I can. If you ever have anyone build you a half decent motor and ask why it cost so much, I can vouch there is a lot of work involved and more then I had realised.
I will continue to update over time and when new things are added or changed. Hope this hasn't been too much in one post and bored people.
Cheers, Kev
Camo Custom Title Time!
1,936 posts ยท joined Oct 2007 ยท
I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!
Click here for my (slowy) modded 1961 Beetle build.
Click here for my (slowy) modded 1961 Beetle build.
