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 Craig S
A.k.a.: Craig
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| posted on December 16th, 2009 at 09:10 PM |
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Novice attempts engine pull down and rebuild - let the questions begin
Hi All,
A few months ago I decided the only way to learn was to buy an old engine, pull it apart and put it back together and get it working.
I bought a 1600tp from 1303Steve and having finished an exam last week I finally found an hour or two to start over the weekend and this evening.
Before attempting to put it on a borrowed engine stand, I decided it would be good to get manifold and tinware off. Manifold was easy, heads look nice
and gunky on the inside, photo below.
However the screw in bolts holding the tinware on are a pain in the buttocks  I've been applying lots of WD40 but still have four left. Is it just a matter of patience, or does anyone have suggestions??
However my main concern at the moment is the engine stand. I have two questions:
- What size (diameter) bolts will I need to go through the case at the top?
- The bolts that are at the bottom obviously stick out from the case by roughly 56-57mm, but the engine stand receivers are longer than the bolt at
about 60mm (photo below), meaning that I can't screw a nut on the end. My guess is that means this engine stand is no use to me. Your thoughts?
Thanks for your help guys (and girls), the dumb questions haven't even begun yet. 
Craig
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1969 Beetle - June
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 matberry
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| posted on December 16th, 2009 at 10:05 PM |
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Give the screws a good crack with a hammer on a strong large screwdriver, then try to undo. If that doesn't work, vice grips or even side cutters
grip around the screw head and undo. As for the engine stand, a pic from further back would help us advise but appears to be not appropriate.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
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Vanders
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| posted on December 17th, 2009 at 09:18 AM |
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I know it's for a type 4 motor, but I found it easier mounting the bell housing to the engine stand.
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Sides
A.k.a.: Dave Sidery
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| posted on December 17th, 2009 at 09:29 AM |
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With the engine stand question, mostly what I've seen done is bolt a nice big heavy flat plate to the plate of the stand, and then bolt the engine
(flywheel removed) directly up to that.
Ive also seen people bolt the flywheel directly to the plate using 4 clutch mounting bolts, but I personally wouldn't try that one - those M8 bolts
are pretty teensie really.
VWDCQ vice pres & web dude - vwdcqinc.org.au
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| posted on December 17th, 2009 at 03:48 PM |
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I just finished mucking about with engine stands and rebuilding, had the same issue with my engine stand. On my engine I found taking the clutch plate
off first then getting some bolts similar to the engine mounting bolts, packed with washers did the trick. I put a wad of rags over the bottom so the
flywheel didnt rub, then carefully lowered it into place with an engine crane. The flywheel could spin freely once I removed the rags and the top two
bolts with the washers held it in place even when I carefully tilted it to the side. Hope that helps. |
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Camo
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| posted on December 17th, 2009 at 04:07 PM |
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Craig,
Where about's in Sydney are you, I have an impact screwdriver.
I'm in the Liverpool area, if that helps.
Send me a PM if you want to borrow it etc.
Kev
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HappyDaze
A.k.a.: Greg Mackie
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| posted on December 17th, 2009 at 04:45 PM |
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A 'make do' engine stand could be trouble. I have one that is made for VW engines. Using a top bolt and a bottom stud, one case half is secured to
the stand, allowing all the bits to be removed and replaced (including the flywheel) without hassles. You can borrow this is you like - I'm in Bowral
though, is that too far away?
Cheers, Greg
I'd rather wear a Beetle out by racing it than by polishing it!
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Craig S
A.k.a.: Craig
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| posted on December 17th, 2009 at 06:13 PM |
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Hi Guys,
Thanks for the replies, I'll keep being patient and applying WD40 and give them some love taps with the hammer, but if that fails I'll take up your
very kind offer Kev. BTW I'm in Blacktown aka God's own country.
Greg thanks for your offer as well, but I think they're reasonably cheap and my guess is that all the local dub shops (Volksbahn, Classic etc) will
have VW specific stands, and if in doubt, there's always Vintage. TrickySimon, where did you get yours?? The cost has already been approved by the
minister of finance, but I was trying to curry favour with her by borrowing instead of buying.
Will post more dumb questions at a later date.
Cheers
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
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jsheppard64
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| posted on December 17th, 2009 at 11:23 PM |
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my last resource for removing stuck in bolt is to weld an easy to find bigger sized rooted hex bolt on top and screw it out
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trickysimon
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| posted on December 18th, 2009 at 07:24 AM |
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Craig, I got mine off ebay. I think the seller makes them.
I'll try and find his username for you.
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trickysimon
A.k.a.: Simon Azzopardi
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| posted on December 18th, 2009 at 07:27 AM |
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Here you go, his username is yasdnil01 on ebay.
Looks like he sells alot of engine stands. Send him a message if you're interested 
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Matt Ryan
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| posted on December 18th, 2009 at 08:20 AM |
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yasdnil01 is a member here too, he doesn't post much though.
Regards,
Matt.
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Craig S
A.k.a.: Craig
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| posted on December 18th, 2009 at 09:24 AM |
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Thanks Simon, I'll try that, I've had no joy with two Sydney shops so far, and trying to get through to a third.
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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colonel mustard
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| posted on December 18th, 2009 at 09:40 AM |
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Try Rod penrose..... I believe he donated the engine stands for Warwick.
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Craig S
A.k.a.: Craig
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| posted on December 18th, 2009 at 10:24 AM |
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Still to get to the guy on ebay (I have to register first before I can contact him), but I've already discovered a conspiracy, no VW shops sell
engine stands because they fear people won't use their workshops. At least that's what I've decided after ringing around several this morning.
One thing suggested to me is that if I get the bench mounted one (which I have tracked down), then the shaft is likely to be the same size as the
engine stand I've borrowed, so in theory it could slip straight in. Thoughts anyone?? Obviously I'd measure the one at home, go to the shop and
check the measurement before buying.
Second question: how necessary is a stand. Apart from getting the oil out (which I could do by sitting the engine on two saw horses), I can't think
of anything else it is completely necessary for, apart from ease of access??
Thanks for your help and ideas.
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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trickysimon
A.k.a.: Simon Azzopardi
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| posted on December 18th, 2009 at 11:20 AM |
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If your splitting the case its gunna be alot harder without a stand to take it apart and put it back together.
You can tilt the engine on its side and sit the crank, cam, rods etc in the half of the case connected to the stand.
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1500S
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| posted on December 18th, 2009 at 06:21 PM |
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| Quote: | Originally
posted by Gwendolyns Master
Still to get to the guy on ebay (I have to register first before I can contact him), but I've already discovered a conspiracy, no VW shops sell
engine stands because they fear people won't use their workshops. At least that's what I've decided after ringing around several this morning.
One thing suggested to me is that if I get the bench mounted one (which I have tracked down), then the shaft is likely to be the same size as the
engine stand I've borrowed, so in theory it could slip straight in. Thoughts anyone?? Obviously I'd measure the one at home, go to the shop and
check the measurement before buying.
Second question: how necessary is a stand. Apart from getting the oil out (which I could do by sitting the engine on two saw horses), I can't think
of anything else it is completely necessary for, apart from ease of access??
Thanks for your help and ideas.
Craig
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The one shown in the pic below is a good strong one. You're a year too late with this one as I gave it to someone at Lalor Park (near you!!) back
then to clean out the shed a bit.
In the new year you may convince me to make another one! Fits the Hafco etc stand.
DH
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Craig S
A.k.a.: Craig
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| posted on December 18th, 2009 at 07:21 PM |
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Thanks DH,
I'm hopefull that I'll get it sorted tomorrow, but I still need to come and visit you to get some other stuff.
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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Camo
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| posted on December 18th, 2009 at 09:58 PM |
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You have to be joking. Look here and go get one in the morning. I saw the bench type ones when I was there the other day.
CLICK HERE then type in engine stand and click search.
Kev
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Craig S
A.k.a.: Craig
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| posted on December 18th, 2009 at 10:34 PM |
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Thanks Kev,
Yes Classic have the bench mount ones, but he told me this morning that he didn't have any of the floor mount ones. So I'm heading over there
tomorrow morning to measure the shaft, and if it is 60mm then it will slip straight in to the stand that I have, and my problem will be solved.
Fingers crossed it is a fairly standard measurement. I'd use it on a bench, save for the fact that none of my benches could take the weight.
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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pete wood
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| posted on December 19th, 2009 at 08:43 AM |
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that stand should be fine mate. do you want me to come round and show you how? give me a call.
alternatively, I have a couple of spare belhousings we could use too.
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Craig S
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| posted on December 19th, 2009 at 06:11 PM |
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Hi All,
Good news and bad news. Went and bought myself a vice grip and some big mother screwdrivers today (I told you I was a novice at these things), and
therefore manged to get the remaining bolts out today, but one of the bolt heads came clean off with the vice grips.  I sat there and contemplated this for a moment whilst staring at
the bolt head resting comfortably in the vice grips, but given that I plan to replace the heads, this is just an annoyance rather than a
catastrophe.
So anyway I took the spark plugs out and the rocker covers off as well, and they seemed cleanish. My daughter kept herself entertained by taking
photos of the progress, the edited highlights of which are below.
More on the engine stand to follow.
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1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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Craig S
A.k.a.: Craig
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| posted on December 19th, 2009 at 06:22 PM |
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The trials of the engine stand continue. 
Prgoress report: Classic does indeed have bench mounted engine stands, but the diameter of the shaft on them is 40mm, and I need a 60mm shaft to fit
the stand I have. So I gave that idea up for today, because I didn't have time to check out your generic motoring shop to see what size the shaft was
on their stands.
I have now sent an email to the guy on ebay and hope to hear back soon.
In the meantime I bought some bolts (M10 - 100mm) and did a trial fit with the gear I already have. I will be removing the flywheel before attaching,
but have to wait until Pete can come around with his 36mm socket and breaker bar, so it's there for the moment.
It bolts up easily through the two holes at the top, and then the bottom bolts can sit comfortably in the lower thingies (technical I know ) although the bottom bolts aren't long enough to peek out the other
side and have a nut attached.
Only problem is that it fouls on the rim of the case (as can be seen in one of the photos below), and when bolted in tightly is likely to damage the
rim. Is this a critical problem? Will I stuff the case if I do this??
Your forbearance of my ignorance is appreciated.
Craig
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1303Steve
A.k.a.: Steve Carter
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| posted on December 19th, 2009 at 06:29 PM |
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Hi
Just find some tube with a 10 mm ID to make spacers for the engine stand out of. Give those top head studs a good soaking in WD40 etc
Steve
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colonel mustard
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| posted on December 19th, 2009 at 06:50 PM |
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Craig, I suggest using an upload site for your photos. Something like photo bucket is great, then you can have many more images in one post 
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Craig S
A.k.a.: Craig
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| posted on December 19th, 2009 at 07:22 PM |
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Hi Colonel,
I have resisted long enough, now a member of photobucket, future posts should look much more snazzy.
Your brother in 1303
Craig
1969 Beetle - June
1974 L Bug - Gwendolyn
2002 Bora V6 4Motion - Anita
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matberry
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| posted on December 19th, 2009 at 10:31 PM |
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The engine stand will stuff the case if left like it is. Some flat shim/steel or ally to pack up the gap could work, but I prefer to have a larger
syrface to bear against and spread the load.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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71-BEETLE-SEDAN
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| posted on December 20th, 2009 at 02:51 PM |
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I dunno bout the stand but ive just started to pull apart a 1200 or 1300 engine to 'give it a clean' and check it out see ow it all works etc,
youll have lots of fun
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yasdnil01
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| posted on January 13th, 2010 at 06:48 PM |
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Howdy yasdnil01 here, I don't post much because I'm the strong silent type ......lol
Yeah I make engine stands, in fact I make several different versions for vw and porsche engines as well as other vw air cooled tools mostly for
type 1 - 3 engines 1100cc - 1600cc
Anyhow if anyone needs a engine stand like a bench mounted one or a free standing floor roll around one contact me and I'll
send some pics and prices.
My engine stands are not cheapo Chinese ones like the other guys sell
Australian made !
By an Australian manufacture
almetal@bravo.net.au
Ohh what another slick bit of self promotion !
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Joel
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| posted on January 13th, 2010 at 07:04 PM |
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good to see 8mm head studs and it even still has the hoover bit, awesome
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