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> Volkswagen Motor Build, Documentary
fiber optic
post Jun 5 2007, 06:26 PM
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Rather than buying a new project at the Super Chevy Show a couple of weeks ago, I decided to burn the money on a car I already own.

Enter one 1957 Beetle Deluxe:




The plan for right now is to pep this motor up a little. New camshaft, new heads, and new carburetors.


The motor as of 4PM today:


The motor as of 7:30 PM today:


The goal was to remove the fan shroud (chrome semi-circular thing in the second picture). It was extremely tough but I managed to get it out. It would have been impossible without the doghouse style cooler. I'm hoping with the shroud and the oil cooler (crusty aluminum thing left of center in the third picture) removed my current jack and jack-stands will be able to get the car high enough to drop the motor. I'll invest in some new ones when I put it back in.

Not sure what I'll tackle next. Probably these dual Webers sitting on the kitchen table. cool.gif
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goota
post Jun 5 2007, 11:51 PM
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you going dual carb?
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fiber optic
post Jun 6 2007, 04:18 AM
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QUOTE(goota @ Jun 6 2007, 02:51 AM) *
you going dual carb?


Yes
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Asher
post Jun 6 2007, 01:21 PM
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Where's the engine again? I don't see it.
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goota
post Jun 6 2007, 11:44 PM
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QUOTE(fiber optic @ Jun 6 2007, 05:18 AM) *
Yes

omg sweet jesus that will be awesome, my little brother has an old bug (71 or something) right now, last time i saw it (couple months ago), it had no fenders and was barely running. Now apparently its all Baja'd out and hes saving to get a 1900cc motor or something with dual carbs. Im not too down with the old VW lingo and parts. But hes making a big deal out of it haha.
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fiber optic
post Jun 19 2007, 06:23 PM
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What it takes to drop the motor out:



Empty engine bay



42mm DCNF Webers



Makes my brother-in-law jealous because his Mustang only has a single crappy 2-barrel. smile.gif


I commissioned a guy in Italy to make me some custom 28mm venturis for the carbs. It's currently got 34mm ones in it and that is way too large for just a 1600cc motor. When I get those I'll rebuild these guys. I've already torn them down but I put 'em back together so I wouldn't lose any of the little parts.

The motor is still sitting on my floor jack. I need to strip some parts off of it to lighten the load so I can lift it onto my engine stand.
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Phix
post Jun 19 2007, 07:12 PM
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QUOTE
I commissioned a guy in Italy to make me some custom 28mm venturis for the carbs.


Holy shit.
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fiber optic
post Jun 22 2007, 08:30 AM
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QUOTE(Phix @ Jun 19 2007, 10:12 PM) *
Holy shit.


???
The only downside is that they're going to take 2 weeks to get here. Should be delivered soon though.

I'm going to take the heads off tonight so I can get the motor off of my floor jack, I need to use it for PM on my truck. With the heads off I can measure the deck height and chamber volume so I can calculate what compression ratio it was running. It required 93 octane using (R+M)/2 method and while I don't really care that I have to use the premium fuel I would like to know what sort of compression I can run. The new camshaft I'm going to use might require that I adjust it.
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fiber optic
post Jun 26 2007, 05:41 PM
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I got my new venturis today. They look freaking incredible. However, getting the old ones out has been a total pain. I've gotten ONE of them out and I gotta do 3 more.



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fiber optic
post Jun 29 2007, 02:50 PM
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For comparison purposes here is one carb with the new 28mm venturis installed and the other with the old 34mm ones.

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White RSX
post Jun 29 2007, 05:34 PM
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This thread is full of win.
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fiber optic
post Jun 30 2007, 08:01 AM
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QUOTE(White RSX @ Jun 29 2007, 08:34 PM) *
This thread is full of win.


Is that a sarcastic remark?
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White RSX
post Jun 30 2007, 09:13 AM
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No.
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fiber optic
post Jul 8 2007, 04:02 PM
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Motor on stand with cylinder heads removed. Freaking domed pistons are going to complicate my deck volume measurement. As it turns out these are only 83mm pistons/cylinders so assuming a stock crankshaft with 69mm stroke I'm only looking at a 1500cc motor. freaked.gif The good thing is that the 85.5mm ones to give me a 1600cc motor will fit without any machine work. After I get the deck height measured I'll pop the cylinders off, remove the pistons, and split the case. I'm interested in seeing what camshaft is in there.
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green73ta
post Jul 9 2007, 03:17 PM
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I'm enjoying this very much!
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fiber optic
post Jul 23 2007, 05:38 AM
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I used some Play-Doh to make an impression of the dome on the pistons and then measured the volume it took to fill. Static compression ratio is a little higher than 9:1. eek.gif

It's been way too hot and humid here so I've been less than motivated to do any work outside.
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fiber optic
post Aug 2 2007, 09:48 AM
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I STILL don't have the case open. I need to take the flywheel off and I don't have the proper tools. I took out the oil pump. It slid right out dry.gif. I was able to see the stamped numbers on my camshaft. 4062 That's a Bugpack brand shaft. I checked the specs on it and it should be a good street cam. Assuming it's in good shape I will just reuse it.

You might be thinking "but fiber optic, if you already have a good camshaft why bother going further to split the case with all of the associated headaches?" I'm going to have to clean it out. That and I bought an oil filter kit. Yes these old cars had no oil filters, just a screen comparable to that on a patio. There's a method to install the filter without disassembling the motor but I don't trust myself to do it right. Besides I've gotten it this far I might as well open it up and make sure everything inside is OK.
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White RSX
post Aug 2 2007, 10:43 PM
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QUOTE(fiber optic @ Aug 2 2007, 09:48 AM) *
You might be thinking "but fiber optic, if you already have a good camshaft why bother going further to split the case with all of the associated headaches?" I'm going to have to clean it out. That and I bought an oil filter kit. Yes these old cars had no oil filters, just a screen comparable to that on a patio. There's a method to install the filter without disassembling the motor but I don't trust myself to do it right. Besides I've gotten it this far I might as well open it up and make sure everything inside is OK.

But fiber optic, if you already have a good camshaft why bother going further to split the case with all of the associated headaches? Raspberry.gif
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fiber optic
post Sep 20 2007, 02:05 PM
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Finally it's cooled off here. I opened the case up on Monday and what I saw was not good. Crankshaft is smoked. Cam and followers look fine. What a pain.

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fiber optic
post Jul 15 2008, 04:17 PM
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Yes, I know it's been almost a year.

At about the time I stopped updating we decided to move to a new house. All of my 'fun money' disappeared to help save for the down payment and moving expenses. Now that we've settled in a bit the work can resume.

There was a change of plan at some point. I essentially decided to scrap the rebuild idea and start from scratch and build the motor I've always wanted. The camshaft is probably the only thing that will remain the same.

2007cc (78mm stroke x 90.5mm bore)
Dual Weber 42mm DCNF carburetors
Bugpack 4062 camshaft (.415" lift and 244º duration at .050")
Full flow oil system
Additional 1.5 quart oil sump

Here are some pictures of the new case.


Bored for 92mm cylinders but I'll be using thick-walled 90.5mm


Clearenced for stroker crankshaft, I'll be using a 78mm counter-weighted one.


Oil pick-up tube extension to accommodate oil sump.


Drilled and tapped oil galley which will allow me to use a canister filter to actually filter the motor's oil.


Tomorrow I'm placing the order for a short-block kit. Crankshaft, rods, flywheel, bearings, seals which should get me started again.
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