1968 Bug 1600SP winter refresh/rebuild

[Z33_Taxi]

Immediately following this engine build I plan to find another engine/case and plan out a second build. I will upgrade my current carb to something a little larger.

For the engine I'll get after this I haven't decided if I want to go dual port or not. I like how smooth a single port is and its reliability. That being said single port heads are getting extremely expensive so a dual port and subsequently dual carb set up will more than likely follow.

[Z33_Taxi]

Finished crank shaft today

Today I returned to Hackel VW( 1372 Central Ave, Albany, NY 12205) to continue working on my engine. We started and finished the crank today, which for some reason was one of the things I was worried about doing myself. This being my first time doing a VW crank I can say it really was a breeze. With the rights tools(I want the Matra Crank stand so bad) and a little oversight I was able to put it together which out much trouble at all. There was any issue with some of the parts which I'll elaborate* on at the end of this post.


Prepping the rods, gears.


tool envy. I want the Matra holder for myself


Initial fit. Put the bearings in and fitted the rods. Put them all on and the torqued to spec.


Next I undid one nut at a time, applied red locktite and re-torqued to spec. Bob told me of a horror store/lesson learned from what he first started out. He told me about a time where he used to put a dab of locktite directly on the threads. He said he stopped doing this, he now puts a dab on his finger and applies, because one time the bottle got away from him and loctite got all over the crank and rods and was an absolute mess.


Heating gears.


Voila. finished crank



*Now for some issues with the parts. All these parts were ordered from Cip1 during their march madness sale by me


This spacer(on the left)had a much smaller passage compared to the stock VW one. After heating the timing gear and trying to press it on it would not fit through the passage. Bob grabbed one of his spare VW ones and threw it on and it fit instantly.

Link to spacer: https://www2.cip1.com/ProductDetails...WC-113-105-219


Next you may notice that the rods installed are not the rods I had in the first picture on the white towel. They came with the bolts preinstalled, were beautiful looking, forged and didnt weigh much more than stock rods. Bob was impressed with them until we installed them on the crank(also purchased from C1pi). They installed easy enough, the bearings fit perfectly, but they were way too tight on the crank. They would not fall on their own. The website says to torque to 30 ft/lb, but they just stayed in place. We took them off and installed VW rods. I will be calling C1PI and seeing if they will give me credit or if I'm going to end up eating the cost.

https://www2.cip1.com/ProductDetails.asp?ProductCode=C18-1254

[Z33_Taxi]

Got everything sorted out as far as the crank goes. Ended up taking the case back apart because I didn't like how it was spinning. Reassembled everything and started putting in all back inside the case.


Lets try this again


Crank in


Cam in(eagle 100)


Dot to dot


Looking good


Sandwich




Checking end play. Bob did it by ear and I asked if he could show me how the gauge works. He said if he was +/- 1 I owed him lunch. I knew I was going to loose. He was right on the money


Removing studs for CB maxi 2


studs out


Goop and sealer


Maxi 2 on


I had pulled a piston out because I wanted to check the rings. He wasn't happy about that and was happy that I just did the one. "I **** dealing with rings, **** it" he said.


The circlips and getting the wrist pins on weren't bad at all. I think the hardest part for me was sliding the jug onto the studs.







wall of misc nos goodies. Has some older parts that are marked Claude's buggies instead of CB. I guess CB used to sponsor Bob when he raced



Soaked and scrubbed my engine tins. Hung them to dry. Will paint after another scrubbing.


Inside the old fan shroud was absoluely a mess. Super dirty/greasy. Switching to a dog house


Cleaned manifold using braided cable and a drill. I saw it on a few build threads. Worked really well.



Going back tomorrow and might finish the engine. Then putting it in sometime soon. Getting excited

[Z33_Taxi]

this is my guy/mentor. Bob Hackel. Ran the #97 VW and won hundreds of races/ beat records

[I_Haz.:R32]

This whole aircooled VW motor thing is blowing my mind. It's super cool to see pics of the assembly process. It also sounds like you're getting a master class here, which must be awesome for you! Keep the updates coming, this is getting exciting!

[Z33_Taxi]

This whole aircooled VW motor thing is blowing my mind. It's super cool to see pics of the assembly process. It also sounds like you're getting a master class here, which must be awesome for you! Keep the updates coming, this is getting exciting!

I'm learning so much. He said he's never taught anyone, but you wouldn't guess that by his patience.

I've always been into cars, but this is by far the most in depth I've gone with repairs and it is so simply. Bob keeps telling me to "use my head before my hands" and use "just a little common sense." The beetle motor is a breeze to work on, parts are easy to come by, but the community is the strongest of any I've ever come across.

[190Evan]

Dude that Squareback dirt tracker is nuts! I would kill to whip that thing around

[Z33_Taxi]

Dude that Squareback dirt tracker is nuts! I would kill to whip that thing around

hell yeah. He set a lot of records in that thing. He still owns it

[Fons]

This build is so good. You're lucky to work with and learn from such an experienced mechanic. Keep up the good work!

[Z33_Taxi]

This build is so good. You're lucky to work with and learn from such an experienced mechanic. Keep up the good work!

thanks man. It's been a learning experience from day one. I wouldn't have gotten as far or as fast without him.

Your E30 estate in awesome.

[Fons]

thanks man. It's been a learning experience from day one. I wouldn't have gotten as far or as fast without him.

Your E30 estate in awesome.

Haha thanks mate

[Z33_Taxi]

Finished painting the tins



The locals are taking their bugs out...I'll be there soon


In for a tune up


My pup decided that I didn't need the carpet kit. It was just the rear part, as I am deleting the rear seat, but still, $90 down the drain.


I saw on another build that someone else had to "trim" down their CB Maxi 2 pump. If I didn't the pulley would have been spinning on the tin. Looks bad, but it will be hidden by the pulley. I also grinded down the bolt because it was hitting it too. Later I had an idea to just cut a slit in the pulley tin. It came out like absolute crap, so I'll be on the hunt for another tin at the upcoming swap meet.



Another tune up. This thing was fitted with all sorts of gene berg goodies.


Stahwille wrench just for tightening down the front manifold bolts.



Almost


test fitting the 36hp dog shroud


Generator in. There are plans for my to convert to an alternator, but it isnt needed right now.


j tubes poking out


The fitment of the 36 doghouses isnt exact, but it isnt as bad as some of the horror stories. I use a little metal tape to fill in any gaps. None of the gaps are larger than 1/4 of an inch.







Engine is put together. Still have to put on the rear part of dog shroud. Install exhaust. Mount coil and that should wrap that up.

For exhaust I went with a SS Empi GT matted to J tubes. I really wanted to buy a vintage speed, but the shipping time doesn't fit my schedule.

Purchased the coolest tar boards from Chris vallone. They are a waffle weave. My best friend has them on his 66 bug and I needed them on mine

http://www.classicvwbugs.com/shop-for-dvds/classic-vintage-vw-volkswagen-beetle-bug-engine-bay-insulation-tar-boards/

Was looking for something to do while waiting for parts. I remembered that my fuel gauge didnt work; so I replaced it. Fit is nice. Install is easy. I didn't take the speedo out just loosned it and was able to reach everything. The aftermarket gauges(bought through JBugs) come with a fine tune adjustment which is nice.




Just waiting for parts now and then the I'll start breaking it in.

[Z33_Taxi]

Last time on the stand



handy little trolly






Motorcycle jack made things easier and harder at the same time

pros
-Steadied the motor perfectly
-Much higher reach. High enough to each the engine stand
-easy to move around shop
-Able to work on motor on the stand itself.
- fit under/around the stock oil pan perfectly
cons:
-Is not low profile. Had to jack the beetle really high, but I was able to slip it under the rear apron
- does strafe. front wheels dont pivot so I couldnt move the jack side to side
- A little harder to tilt motor, but I'd rather it be steady

[/img]


Changed the trans fluid. Used Castrol 85w90. I forgot how much gear oil smells.


After 3 hours of pushing, pulling, yelling, swearing, some unsafe practices. The motor went in



I used this break in procedure:

http://www.aircooled.net/vw-engine-break-in-procedure/

When building the motor I used a generous amounts of oil and grease on the oil pump gears. This was advised to me so that when everything primed it would be nice and smooth.

It was super easy. Oil pressure came in immediately as did fuel pressure.

I can say the scariest part was running the motor at high idle. Super loud, smells of freshly painted tins, some smoke, but no oil leaks. no fuel leaks.

I had some issues with the wiring, replaced the points, static timed, adjusted my carb and ran the motor again. CHanged the oil and adjusted the valves. Voila.

Here's a small video of it at idle.
[youtube]https://www.youtube.com/watch?v=2X1COWiSaUg&feature=youtu.be[/youtube]



I want to thank everyone for the encouragement and help along the way



[b] What's next is drive it around for the next few days. Continue working on the interior and prep for my trip to Carlisle car show. 300ish miles each way. I'm going to attempt to stay off the highway as much as I can and take country roads

[Z33_Taxi]

This morning I went to drive the beetle to get some milk and fill the tires with air. I got about 100 yards when the car stalled out. I tried restarting thr car, but it only cranked. When i checked the rear I noticed smoke and the smell of electrical. It was the main wire going to the + side of the coil, it was roasted, as was the wire going to the fuel aolenoid on the carb.

The PO added a new section of wire at the rear firewall from the main black cable; seems it had broken and they just ran a smaller cable.

My question is, short of a new harness,which will be on order after typing this, what can I do? I had a trip planned in the beetle for next week and Ive been working all winter for this. I'm thinking of going farther back and running just that one cable. OR doing what the PO did,but wiring it better and with the appropriate gauge wire. Any help would be appreciated


Soultion:

https://www.thesamba.com/vw/forum/viewtopic.php?t=678440&highlight=

[Z33_Taxi]

I wish I saw this thread, https://www.thesamba.com/vw/forum/vi...439461#8439461 , a week ago. First time owning a beetle and I have definitely learned to buy parts for the beetle you own not the beetle how it was stock. I have a 71+ engine, but the original trans. SO what did I do? Buy a 71+ clutch kit. Installed it and magically it even drove for a bit. Now I'm dropping the engine again and using the old pressure plate.

70 and below beetle have a centering ring on the pressure plate, where as, 71+ don't and instead of a centering shaft/guide on the trans

Correct PP


Incorrect: