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Idiots/virgin Guide on "How to" build a BIG engine...

98K views 625 replies 62 participants last post by  Wigglesworth 
#1 · (Edited)
Howdy doody folks,

Welcome to this ere midlife crisis Engine build thread of mine.

My reasons for doing this thread are to help those folk out there,who,like myself, have NO idea of how to build an Aircooled VW Engine,that want a BIG engine but cant afford to have one built by a pro'.
I've seen tooooooo many threads,about dodgy Engine build companies so i thought why not do it myself....after all is it really such a secret dark art?
And finally,i want to prove to MYSELF that I can do it:D

I hope,during this thread,to try and explain those bits that confuse folk or stuff that is foreign to us virgin engine folk...

Now i have NO VW Engine experience....nada...niet..none AT ALL...

My background before making whisky is all Aircraft engineering,so i am hoping to use my 20 odd yr engineering experience to get me thru this build.

Hopefully along the way, i will be able to answer/explain those questions we ALL have........for example.....what does CC size mean in relation to heads.....welded behind number 3,on an engine case...what torque settings.....why do we need to balance bits and what bits to balance and so on........

This thread WILL be done in SLOW time,by this i mean,it may be a while between up dates,as i will be having stuff sent away for balancing and plus im a shift worker too.
EVERYTHING on this build will be done by ME,unless it is to do with balancing or specialist stuff is needed.

TOOLS/EQUIPMENT- i will list what specialist tools i need to buy and why........but i am starting off with my Blue Point tool chest.

Engine bits- ALL and i mean ALL my Engine parts are being supplied by James(beetleragtop) on here...........Ive been planning this build for nearly 2 yrs now and have done a LOT of reading into different suppliers and people.James without doubt came out as my choice.Aswell as the knowledge and contacts to get the parts his PATIENCE and good manners when dealing with myself have been Top Notch.No question is too silly and he always makes TIME to either PM or speak in person.....i can NOT fault the guy in anyway.

So,what am i gonna build?

Simples.....................im building from scratch a 2276cc Turbo engine...........:eek::crazy::D

Over the past 18 months or so ive been buying my bits for the build.
I am now nearly there,ive just my Pistons n Barrells to buy,ignition system and cooling system.........

The Spec.................

The Case....

is from CB Performance. The pick up tube is included. 8mm case savers. Features: - 6 Shuffle Pins for added strength - Raised deck surface 7mm to eliminate the usage of Barrel Spacers or custom long cylinders - Drilled & Tapped for Full Flow - Cut for Grooved Cam Plug - Filled in behind #3 - Clearanced for 86 stroke Crankshafts

Cylinder heads....

jeff denham. Valve size is 44x37.5(these are 2nd hand and refreshed and pushed out over 200 BHP on a NA engine)

Crankshaft-Super Race 82 mm stroke VW journals

Camshaft - Engle TCS20.............cut for a turbo apllication

Conrods- superrace 5.5 VW Journal

Rockers- Scat pro-comp forged 4340

Flywheel- forged chromoly lightened 8 dowel

Kennedy stage 1 200mm pressure plate.

Gland nut- CB performance

Pushrods- Manton cut to length

Push-rod tubes- Scat adjustable

Cam gears- CB Performance billet straight cut

Serpentine pulley kit

Berg cooling fan

Turbo- draw thru turbo using a Garrett A/R 60 M24 and Spanish Webber 45 DCOE

BHP....How much will i have? how much do i want??
I dont have a scooby.........really i dont............my attitude to the BHP question is simple.............what will be,will be.......I do NOT have a set figure in my head.

Info- as and when i can,i will add to here any usefull info/books etc

Prices................to be honest ive not added it up yet,HOW EVER,i will NOT be adding prices to this list as this is between myself and beetleragtop.......;)

Thankfully i have an incredibly understanding Mrs who puts up with all my pipe dreams and projects.....thank gawd!!:hug:

I will be starting this build in my spare bedroom,so i have a clean area........and this was the WIFES idea!!...really it WAS !!!:D

So,after all the spiel ^^^^^, it's time for me to get back to my reading and for wait for folk to tell me im a fool/idiot/knob and wasting my money on this build........:D

Please, feel free, to add to this thread once i get started,be you an experienced engine person,or,a virgin like myself......it will only serve to make this thread better for EVERYONE to use and get benefit from.

Will I succeed,or, will I fail in spectacular stylee ??.......I really dont know,so, why dont you sit back and watch/read and join me on my journey, i am sure its gonna be very fucking scary lots of fun!!!

And at the end of it all, i shall be fitting it to my newly acquired 69 Ghia.........................i have NOT set a target date for this...it will take as long as it takes..............

That's it then.......all thats left for me to say is..............let the fun begin...(oh and for you lot to say a prayer or two for me)

Keep smilin y'all

Mario:D
 
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#5 · (Edited)
Terms... terminology.....phrases........What they mean..

In this section i will add phrases/words/terms etc and what they mean.....i will edit this i add more to it........

REMEMBER...this all refers to VW Aircooled engines...so they may have more or different meanings elsewhere on other types of engines.......;)

Blue-printing- refers to the balancing,machining,measuring and attention to detail of the parts making up the engine..
Short block-refers to everything contained in, and including the engine case (crank, rods, cam, lifters, etc)
Long block-Same as short block PLUS Barrels/Pistons Cylinder heads pushrods/tubes
Deck height-Deck is the distance from the top of your piston to the top of your cylinder wall when the piston is at the top of it's stroke
Case savers-A double threaded insert which is used for the head studs to help prevent the threads from getting pulled out over time.These are fitted to the case.
Porting-is when you carefully grind away this un-necessary material smoothing the flow paths for the intake and exhaust gasses
Polishing-is when you polish the surfaces of your combustion chambers and exhaust ports, making it easier to ingest and expel gasses
End play(float)-is the slight amount of fore & aft movement that your crankshaft is allowed to move in the main bearings when your engine is cold.
STATIC balancing-
DYNAMIC balancing-
CAMSHAFT lash-This is the movement between CAMshaft gears and CRANKshaft gears
SHUFFLE PINS- refer to PIC on page 17 post 162

LUBRICANTS/SEALANTS-PAGE 37

Case sealant...Permatex
Barrel sealant...Permatex RTV
Assembly Lube..Brad Penn
Cam shield paste

Please note...i am NOT making these up,these are terms/phrases i am coming across during my research...
This list^^ will be updated as and when i get chance,so WILL change

PLEASE FEEL FREE TO TELL ME IF I'VE GOT SOMETHING WRONG......there is NO point in me putting in WRONG info

PICS OF MY ENGINE PARTS ARE ON PAGES 4 n 5 and 8.............TURBO PICS PAGE 8

ITEMS for DYNAMIC BALANCING PAGE 12

INTERNALS OF CASE PAGE 16,17

CRANKSHAFT GEAR ASSEMBLY PAGES 32 33

Crank and cam shaft trial fit with clearance checks PAGE 35

How to VIDEO......cam shaft LASH PAGE 36

How to VIDEO...Cam shaft THRUST clearance...plus pics...PAGE 37

Cam shaft Thrust bearing clearance PAGE 43

Setting END PLAY PAGE 43

con rod side play PAGE 43

CON ROD assembly PAGE 43

CRANKSHAFT oil gallery allen bolts PAGE 43

CRANKSHAFT and CAM SHAFT fitting PAGE 44
 
#6 · (Edited)
Reference points.....where to get the info..books etc..

In this section i will add where i am finding my info....ie which books i find usefull....which website etc(websites will only be added if it conforms with VZI rules)

Turbomania...by Bob Tomlinson
Aircooled VW Engine interchange manual...by Keith Seume-http://www.amazon.co.uk/Aircooled-Engine-Interchange-Motorbooks-Workshop/dp/0760303142/ref=sr_1_1?ie=UTF8&qid=1324722115&sr=8-1
VW Beetle Performance handbook...by Keith Seume-http://www.amazon.co.uk/Beetle-Performance-Handbook-Motorbooks-Workshop/dp/0760304696/ref=sr_1_2?ie=UTF8&qid=1324722115&sr=8-2
How to Hotrod Volkswagen Engines...by Bill Fisher-http://www.amazon.co.uk/How-Hot-Rod-Volkswagen-Engines/dp/0912656034/ref=sr_1_1?s=books&ie=UTF8&qid=1324722406&sr=1-1
How to Rebuild your Volkswagen Aircooled Engine...by Tom Wilson-http://www.amazon.co.uk/s/ref=nb_sb_noss?url=search-alias%3Dstripbooks&field-keywords=How+to+Rebuild+your+Volkswagen+Aircooled+Engine...by+Tom+Wilson&x=10&y=23
A performance Guide for the Aircooled Volkswagen...by John Maher Racing-http://www.johnmaherracing.co.uk/performanceguide.htm

WEBSITES

http://www.shoptalkforums.com/viewtopic.php?f=3&t=125546

.

ALL of the books mentioned i have purchased myself and none of it gained by dodgy internet downloads
 
#22 ·
(websites will only be added if it conforms with VZI rules)
Links to sites are not a problem, especially if they are a technical resource, we only frown upon links to other forum.

You can also help others by linking directly to the books on Amazon if they are listed there.
 
#9 ·
YOU are one of the people i am aiming to help by doing this then:D

PRICING................i had a feeling this would maybe crop up.....what i will do is once i have purchased ALL the items for the build i will put up an approx price for EVERYTHING.........

Please NO-ONE take offence by me NOT putting up prices,but, i have to consider James(beetleragtop).
The fella has his costs etc to consider so i do NOT want to risk harming him or his venture...............

Plus YOU might get a better deal than me:incheek:

I am sure James will be along at some point and read this,as ive sent him a link to the thread;)

Mario:D
 
#8 · (Edited)
Please feel free

To add any books....videos etc you think may well help...i will edit and add them into my posts up there^^^^^^

And feel free to add ANY INFO you think will be of help...i will put it into the relevant post......ie book or phrase/term etc

Remember the MORE info then the better and this way WE help build up a decent amount of good genuine info in the SAME thread,all in one place,rather than chasing all around the internet;)

Thanks

Mario:D
 
#12 ·
Subscribed, looking forward to this one - if your un-squishing of your split is anything to go by, you have the right sort of attitude, willing to have a go, yet careful and thoughtful in the way that you do things.

Sounds like a good spec you're looking at there, be great to see it develop.

All the best Mario!

Colin
 
#15 ·
Thank you for the kind words Colin:D
I am hoping i can come up with the goods on this thread too and it turns into a useful tool for ALL to get their questions answered.
I fully intend taking my time with this as i have LOTS to study and learn,also various parts will have to be posted out to various companies for balancing etc
So,with luck this thread will turn into an info thread on how to build an engine,what the terms/phrases mean, which books/videos and finally which companies to use:D

I have a metric micrometer dial gauge you can borrow.
You need to measure everything much more accurate if your blue printing a big spec engine.
It will need a magnetic mount (About £10-20 on fleabay)
A very useful tool when it comes to matching con rod lengths,piston deck hight and crank end float.

I also have a few alloy intercooler pipes 2.5 inch diameter and a foot long. An old rover turbo intercooler and other odds and sods that might be useful.
Ah,Phil,in your first post you highlight some of the tools i need to acquire as you are spot on with the accuracy of measuring etc.
Plus i will need a digital weigher aswell;)
I may well take you up on the offer of loaning the micrometer altho my intention is to acquire the tools as i need them;)

Pipes etc..........i may well take you up on those,i will have to measure what i have......as my turbo system comes with all pipes:D
I start back on shift tomorrow afternoon for 5 days so i am hoping to get pics of the parts i have so far....this way i can show before and after pics( not that there will be much if anything to see on the after pics;))

:D
 
#13 · (Edited)
I have a metric micrometer dial gauge you can borrow.
You need to measure everything much more accurate if your blue printing a big spec engine.
It will need a magnetic mount (About £10-20 on fleabay)
A very useful tool when it comes to matching con rod lengths,piston deck hight and crank end float.

I also have a few alloy intercooler pipes 2.5 inch diameter and a foot long. An old rover turbo intercooler and other odds and sods that might be useful.
 
#19 ·
Top man. I built my own engine after hearing all the garage horror stories and it was the best thing i could have done.

Can we hav plenty of pictures as Im lazy and can't be bothered to read:incheek:

Good luck
:lol::lol:
yup there will be plenty o pics just for you lazy sods:lol:

And good on yer for building your own:D

Any tips you have feel free to chuck em on here;)
 
#18 ·
Looking forward to reading this. Built my 1600cc Singleport earlier this year, that was enough for me:lol:
Any chance of a cheeky pic of the lucky car this monster is going in?
Good luck. Il be next to useless technicaly but will be watching with interest.

Rich
 
#21 ·
Ahh the car its going in...........erm....well.............its NOT here yet and that needs FINISHING too:lol::lol:
So,you see, this is another reason why it wont be a quick build:lol:
Car is getting delivered on 16th Jan,so i will get some fresh pics of her up in another thread;)

No worries Mario. I will be glad to be able to help.
I have used this set of scales to balance a set of con rods so I can vouch for it's accuracy. It can weigh up to 1kg so is more than man enough to weigh your pistons and rods.
http://www.ebay.co.uk/itm/Digital-P..._Measurement_Equipment_ET&hash=item27b9a8bad1
You will need a small engineers table to measure the rod length and wrist pin to piston top hight (using a dial gauge).
Cool Phil,thanks for this^^^:hug::D
 
#20 ·
No worries Mario. I will be glad to be able to help.
I have used this set of scales to balance a set of con rods so I can vouch for it's accuracy. It can weigh up to 1kg so is more than man enough to weigh your pistons and rods.
http://www.ebay.co.uk/itm/Digital-P..._Measurement_Equipment_ET&hash=item27b9a8bad1
You will need a small engineers table to measure the rod length and wrist pin to piston top hight (using a dial gauge).
 
#37 ·
Yup she is a top woman....altho i do foresee problems building this in the bedroom..not with the wife but with the build itself....i will explain as and when i come to them;)

:lol:...if the pressure wasnt on before it is now:lol::hug:

I'm gonna follow this for when i get around to doing mine.

I think this will be great for people like me, Your and others who want to attempt it but just are not 100%.

Craig
hopefully i can do the thread justice fella,as it will help a lot of folk out,which is why i am doing it:D
 
#38 ·
aha,my 1st technical question:eek:
answer.......really simple....
1. i already have the draw thru turbo kit..
2.altho i have no fixed price in my head for this build(which is why its taking so long as im saving up for each bit of kit) i still want to try and consider my mrs....so for now i dont have the extra expense of buying in EFI kit....(for now;))

yes this is the thread us total zero info engine heads have been after!
when peeps say they are ''subscribed'' do they actually mean they have a way of knowing when a new post is made or is it just a saying that they will follow it:incheek:

good luck and an engine build is something id love to do and try so when ive built one the awsomest 66 bugs by next summer ill want to try an engine build so cheers duuuuuuuuuuuuuuuuuuuuuuuude :hug:
again you are another person i am aiming at helping...like you i have NO idea..........i am doing LOTS of studying...and will be asking lots of questions;)

Hi mate at the top is tread tools go in there and go on subscribe to tread
Just thought id help
cheers for that,now i know how to do that too:lol::D
 
#34 ·
yes this is the thread us total zero info engine heads have been after!
when peeps say they are ''subscribed'' do they actually mean they have a way of knowing when a new post is made or is it just a saying that they will follow it:incheek:

good luck and an engine build is something id love to do and try so when ive built one the awsomest 66 bugs by next summer ill want to try an engine build so cheers duuuuuuuuuuuuuuuuuuuuuuuude :hug:
 
#39 · (Edited)
The kit.........in pictures

Ok,now its time to show you what ive been sleeping with.....nope NOT the wife:)eek::lol:) but THIS lot.........(yes it really IS being kept in my bedroom:D)

The case..........BRAND SPANKING NEW







BERG FAN.........lightened and balanced





 
#42 ·
i dont know why,but,photobucket has loaded some pics upside down:rolleyes:..sorry...

i do have more kit....bearings, shells etc.....but i will show them later in the build as and when i need/use them:D

Right i am orf to sit in the corner and wring my hands together worrying about the amount of folk looking into this thread and hoping to fuck i get it right:lol::lol:

Keep smilin y'all and HAPPY XMAS:hug:

Mario:D
 
#47 ·
BUILD IT>>>BUILD IT........go on i DARES you:lol:

fair comment on the EFI.

also, ive no experience on the cam/lifter combo's but theres generally not a great deal of good press on STF and The Samba about those 'lube-a-lobes' people tend to go for cb or engle lifters with engle cams, like i said though no first hand experience
Yup ive seen the stuff about the lube-a-lobes.......when the time comes and im not happy/confident in them....then i will change them....i STILL have LOADS of studying to do and MASSESS to learn and digest.....i REALLY want this to be done right for everyones sake..if im not happy with anything then i will re-search it again and if need be change it:D

Epic thread man, just what I needed to get me motivated.
Good stuff glad ya like:D
 
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