Hi guys'n'gals,

Just having a look through the world wide web at all the parts I have readily available for when I hopefully start part one of a project in the coming month and I have to say I'm really quite confused!

Basically I am looking to build a simple 1500-1600 engine, bigger is ok but I want enough power for it to happily accept highway touring (90-110 if possible), but simple enough that it should serve itself useful for a long time if looked after well.

*With my searching EMPI parts seem to get a bad wrap, is there a reason?

*I would really like to use Mahle pistons and jugs, but not sure how to match up all the sizings for what I want? should I chat with CVD/other companies directly to help with this?

*sizing sizing sizing! I've rebuilt a few bike engines and its the one thing I always get flustered at, trying to match heads to cylinders to pistons and etc, especially when going oversize. Is there any simple kits that contain everything? or should I just tough it and buy pieces individually (I noticed CVD had a pobjoy 90.5 case, also a 1776cc kit based off this, but using AA pistons/jugs etc, has anyone experienced the quality of these?)

Sorry to ask these types of questions, but im just baffled at the moment haha, and think its best to get all this behind me before I even decide what to look for with this project.

Hi there

Lots of good info here
http://www.aircooled.net/gnrlsite/resource/articles.htm 

EMPI - VW people have a real passion for buying cheap shiny bits. This is where EMPI comes in. Generally their bits are cheap and shiny

With a 69 crank
85.5 - 1600
90.5 - 1775
94 - 1916
Use the engine size programme on the aircooled.net site and and see the different engine combos

Pobjoy stuff is good. Not so sure about AA. Have heard of poor quaility here. Just dont know if you can easily buy Mahle

That CVD website has 90.5 Mahle pistons/jugs, and theres some nicer looking H rods on there, with Pobjoy prepped cases so I might have to head in that direction. And thanks for the link to the website will help me greatly I am happy to handle EMPI stuff as long as it will actually work, I won't be needing genuine stuff so its basically "what will work best for the situation" and save me some overall budget. 85.5 sized stuff is dirt cheap, but the mahle stuff I can only find easily in 90.5.

No troubles, just a little more torque I guess

us dollar is poop so its a good time to buy from vwparts.net

Thanks for the site as well Cnfabo, and bizarre, the reads on aircoolet.net are fantastic, ALOT of what I was wondering has been explained. Looks like, with some more reading and thinking I'll be heading towards;
-90.5 pistons and jugs
-Either close to stock, or go 82mm for the crank
-good H-rods
-Some decent dualport heads
-The typical stuff like lightened flywheels, good ignition gear, dual carbs etc.

The leftover work; everything from if it will need to be decked (and still fit in the engine bay) or not and exact parts :P . Thanks for all the help guys

keep this thread alive i would be keen to see what you do as I will be doing similar next year. My dream would be to buy a Stan Pobje engine but depending on cost

Damn my net, as I was trying to post I just priced up the following on vwparts.net, but will have to check local pricing as the postage seems to be the killer (if it wasn't for that, I'd be fine ordering from overseas).

On a lighter note, I've done some searching on AA products and their pistons seem to get the thumbs up in the US. Apparently they are all micro weighed before packaging to ensure every set is perfectly matched in weight, and it apparently is true!

4140 forged crank 69 to play it safe - $181
4140 forged I-beam rods $176
AA pistons and jugs 90.5 $167
Teflon wrist pin buttons

Total price $534
Delivery, Slow $289

$823 for all that is a great price in my mind, but if locals can come under 1K for the same kit then I would buy local, it means somewhere I can PHYSICALLY go if there is problems with the parts.

Ok should be about 1 month before I get some parts together and pick up a little beetle, can someone rate the following and tell me if they would suggest otherwise? Its going to be for street mostly, nothing special.

-4140 69 crank with 4140 I-beam 5.4 rods (or should I go a 72-78 crank with 5.5/5.6 H-beams?)
-AA pistons and jugs 90.5mm
-AS41 90.5 case machined by Pobjoy
-Engle W100 Cam (or a W110?)
-CB 044 heads 40x35.5
-The engine kit comes with A lightened chromoly flywheel. thrust cam bearings, rod bearings, and gasket set
-dual Brosol/Solex 40mm carbs "kadron" kit.
-009 distributor and ignition gear, unsure if I want mech or vacuum advance, I haven't had to deal with distributors in over half a decade haha.
-Basic GT style exhaust, something that will fit in the stock openings.


From here, I have no idea what else I need to complete one of these engines, I will be off to buy a book I guess, the above I am fairly set on as a basic combination though, probably ask the local bug stores too. I'm assuming I'll have to buy suitable pushrods/tubes/rockers as well as it looks like the heads dont come with rockers? Then a camgear and what about the gearsets that attach to the crank, do I re-use the stock ones or is there new aftermarket sets?

edit: oh and obviously will need a new set of head studs, after I find out if that case is 8 or 10mm.

And paul I didn't notice your only up the road from me basically, haha, I'm near park central.

I know someone selling a beetle if your interested, just sent you a PM

replied

If you do go a stroker get a 78mm with 5.4" rods this will keep the engine width down and be easier to fit, run with a w110 cam and set your compression to 8.5-9:1.