The final part of this series covering the rebuild of a dual relief twin port 1600 Volkswagen motor. In this video fitting the fan housing, tinware and exhaust as well as a test run.
I think everyone who has love for cars, VW or not, should take care and love for what he does. That's love for cars, this is love for VW! Brazilian greetings.
Going to be starting a 72 here in a week, hopefully won't have to go this far but was great seeing a true start to finish build. As a buddy of mine from Queensland says " Cheers mate"
dude ... am passionate about engines. When I saw your videos, riding vw engines went crazy. simply amazed ... speechless. I am unable to take courses to learn how to do what you do, but just to make you see, was a great gift. The grand prize went to see it in operation! spectacular, congratulations for the work. If one day God will bless me with a good job, I will realize my dream and start a business, to be able to mount my motors, just as you did in the videos ... thank you!!
Great! Like many others I used to do a total rebuild of these engines right in the communal university parking lot in the 70s. Having a workshop is sooooo upscale! ;)
I have the Haynes too and whilst it is pretty good I think it is worth noting that if you are rebuilding with used parts the Bentley book is much better, not only are there more diagrams and information, but a whole load of info on wear limits for all the parts so you can truely KNOW if you need to replace something or not. PS great vids btw, thanks for putting the time in to make these
Congratulations on a great job. I have a VW1600 engine dual carburetion car here in Brazil called Brasilia. It is an inheritance from my father in 1978. already bought all the parts of the engine mount and I intend coming next year, with a mechanic friend of mine, but seeing his mount was jealous, congratulations again. Best Regards and a happy 2014. Luiz Antonio
I cleaned the cases in a large parts washer with a synthetic cleaning solution - diluted type easy to get in many stores. Sealant I used is CRC grey silicon, works really well and cleans up better than a lot of those red ones. Took me about four days to rebuild it once it was cleaned and all the machining was done, probably took similar time to strip it down and clean it :)
A lot of the internals are identical, just the location of the external items and the cooling fan. Best way to do it it to have a go and take your time dismantling it. And get yourself a good workshop manual like the Haynes or Bentley ones. Good luck.
Your video has made me want to do my rebuild myself. It is hard to get anybody to do any kind of work around here anymore. My only fear is once I do it, something will be wrong inside the engine somewhere. Then I will have to take it to a professional. Other than that, it looks pretty easy doing it. Great video. I have seen many kits on the internet and Hot VW magazine. It seems for 500 dollars, you can get all of the parts needed. Otherwise it is 1200 for a rebuilt engine.
Yes really like them, I used one on my ratty 1500 too. Nice VW type noise but deeper. It is a bit noisy in this beetle but was good in the 1500 and I haven't finished the sound-proofing yet.
Yes the vw motors are ideal for all the reasons you list and when they started making beach buggys and off roaders in the 50's and 60's they were also cheap and readily available. The exhaust goes out the back bottom and the air comes in the top so keep them apart and no worries. Power output varies but wasn't a lot standard on these, I think the 1600 twin ports must be around 50 HP. You can't beat natural aspiration and a distributor-coil ignition for simplicity :)
Great Videos!! You make it look so easy. My 1600 engine broke a Cam yesterday. Would you recommend a total rebuild or a partial rebuild. The engine was rebuilt less than 4 years ago.
Yes - it's actually called an "align" bore but everyone mispronounces it as "line bore" including me. They use a mill-type machine and run a specially made tool through the bolted up cases and take a few thousandths of an inch off the bearing surfaces. You can buy fractional oversize bearings to match. Best to go to someone who has done it before and has the special boring bar as there is no room for mistakes :)
That's going to be a messy rebuild - depending on where the cam shaft was you are going to have bent valves and punctured pistons so you should probably split the cases to get all the bits of metal out. While it is open check the crank shaft wear but if rebuilt 4 years ago should still be good if they did it then. New barrels and pistons would be the minimum. Good luck with the rebuild.
Yes stainless tubes - not sure if it's a good idea as they will be less flexible but they are working well and look nice forever unlike the rusty old steel one. Time will tell...
Hey mate, sweet vids. Just rebuild my 1600, put it in and upon start up all good, then engine noise changed and became internal and deeper, pulley started to move in and out and a bit off centered, then brown oil from the fly wheel area came out, pulled the engine and bell housing wet as, oil seal stuffed. Ideas of what happened? Gland nut was not that tight, what about too much endplay, the shims not correct? Help!!
@astro1218 Thanks, the fun - like building VW's and motorbikes - is in the making for me so it doesn't really matter :) Still nice to get good feedback every now and then.
Olá Sou do Brasíl, tenho um Buggy e este seu vídeo de como fazer o motor é sensacional, grato pela boa vontade de produzir este material. :) Abraço. Marcus Valdetaro
My machinist did skim the fly wheel when he did the line-bore and I had to adjust for it by adding shims. I have a video of it here somewhere showing how to set it up.
Just wonder, are there any vw engines for the beetle/bug (originally fitted) that has hydraulic lifters in them? Is it possible to do this to the ordinary engines that in the bug? Just curious...
Great video ! I was thinking of using a 1600 engine in a buggy, could it work ? It Could be quite practical since the engine is using no electronics, no coolant (I think it is air-cooled right ?) and by being a "flat 4"it is low and in not cumbersome not heavy. however, something is bogging me : is the air intake and the exhaust in the same compartiment ? And also : approximately, how much hp is it producing ? is it a petrol or diesel ? sorry for bothering :)
May mate great vids! I'm Rebuilding my engine this week for the first time and was wondering how many hours it might take for a first timer to assemble and install, also if you had any tips for cleaning the case and what sealant to use. any advice would be awesome and again your videos were great :)
Haha yes it is a bit monotonous. It doesn't need the audio so just mute it I guess. You can't use anyone else's music these days without getting in trouble with the man so unfortunately it is just whatever I can knock up at the time. I'll try to tame it down a bit for the next one :)
Is a line bore a machinist sticks a drill through the center and cuts out any unround surfaces for the crankshaft to rotate on? What is involved? Thank you.
See how much end-float it has by pulling the front pulley back and forward, 1/8" is a lot but if you barely feel it move then the bottom end is probably OK.Change the oil and clean the oil filter and then turn it over for a few minutes with the spark plug leads off. If it turns over smoothly connect the leads and try and start it. If it starts let it idle for five minutes and see how much crap comes out the exhaust. If it idles ok then set the tappets and test drive it. :)
hey sir, congratulations, your vids are amazing. Could you tell me why your vw 1600 bug have a differente song on the exhaust? Is a kind of explosion with air. Its a kind of whistle. How do you do it? near of 3:31 you can listen. thanks anyway :D
The electronic ignition would improve the throttle response because with that, you are eliminating your points, condenser and vaccum therefore getting rid of the mechanic advance setup improving throttle response, i have the setup on my VW sandrail.
i am getting a 71 vw t2 for free with the engine not in the car. the guy giving it to me said he was told it was running when pulled, but that was years ago. so my question is would a full rebuild be necessary in my situation. or should i just put it back in and try it. and help would be appreciated
Yes but what's the worst that can happen? You can remove the engine yourself and strip it down. The only thing you need to farm out is the line bore if it needs one. If you are in the States the parts to do a full rebuild are so low even if you buy one of the rebuild kits. Just aim to make it stock or slightly warm and you can't go too far wrong and if it turns to custard you can always take the box of parts to a pro :) they will have seen it before.
I use the Haynes repair manuals as my reference, they cover most of what you need to know- the rest is inspired guesswork :) Search Amazon for Haynes VW manual.
Yeah I know it must be weird shifting with your right hand. Two-thirds of the world drive on the right now so it is probably about time they standardised it :)
![“อาร์ต พศุตม์” เกือบเอี่ยวทุกคดีดัง เอ๊ะไว้ก่อน ไม่มีอะไรได้มาง่ายๆ | แฉ 16 ต.ค. 67 [2/3] | GMM25](http://i.ytimg.com/vi/0Gx-0-kUBv8/mqdefault.jpg)
I think everyone who has love for cars, VW or not, should take care and love for what he does. That's love for cars, this is love for VW! Brazilian greetings.
Going to be starting a 72 here in a week, hopefully won't have to go this far but was great seeing a true start to finish build. As a buddy of mine from Queensland says " Cheers mate"
dude ... am passionate about engines. When I saw your videos, riding vw engines went crazy. simply amazed ... speechless. I am unable to take courses to learn how to do what you do, but just to make you see, was a great gift. The grand prize went to see it in operation! spectacular, congratulations for the work. If one day God will bless me with a good job, I will realize my dream and start a business, to be able to mount my motors, just as you did in the videos ... thank you!!
Watched all 4 of your engine rebuild videos. TRULY inspiring! Excellent work!
Was a joy to watch the whole series. One thing though, THE STEERING COLUMN IS ON THE WRONG SIDE MATE!!! LOL!
A sincere thank you from Texas. These videos were GREAT. Loved the music as well.
Great! Like many others I used to do a total rebuild of these engines right in the communal university parking lot in the 70s. Having a workshop is sooooo upscale! ;)
I have the Haynes too and whilst it is pretty good I think it is worth noting that if you are rebuilding with used parts the Bentley book is much better, not only are there more diagrams and information, but a whole load of info on wear limits for all the parts so you can truely KNOW if you need to replace something or not. PS great vids btw, thanks for putting the time in to make these
Hoy termine de ver los cuatro capítulos y están sensacionales lo disfrute mucho.
That's good stuff. I loved doing that almost 40 years ago. Thank you for that.
Se ve que es un buen mecanico automotriz todo lo hace detalladamente y con dedicacion.
Congratulations on a great job. I have a VW1600 engine dual carburetion car here in Brazil called Brasilia. It is an inheritance from my father in 1978. already bought all the parts of the engine mount and I intend coming next year, with a mechanic friend of mine, but seeing his mount was jealous, congratulations again. Best Regards and a happy 2014. Luiz Antonio
I will feel safe knowing a person like you did my enjin well done
awesome!!!! totally awesome, i loved the door's security system!!!!
I cleaned the cases in a large parts washer with a synthetic cleaning solution - diluted type easy to get in many stores. Sealant I used is CRC grey silicon, works really well and cleans up better than a lot of those red ones. Took me about four days to rebuild it once it was cleaned and all the machining was done, probably took similar time to strip it down and clean it :)
A lot of the internals are identical, just the location of the external items and the cooling fan. Best way to do it it to have a go and take your time dismantling it. And get yourself a good workshop manual like the Haynes or Bentley ones. Good luck.
Your video has made me want to do my rebuild myself. It is hard to get anybody to do any kind of work around here anymore. My only fear is once I do it, something will be wrong inside the engine somewhere. Then I will have to take it to a professional. Other than that, it looks pretty easy doing it. Great video. I have seen many kits on the internet and Hot VW magazine. It seems for 500 dollars, you can get all of the parts needed. Otherwise it is 1200 for a rebuilt engine.
Yes really like them, I used one on my ratty 1500 too. Nice VW type noise but deeper. It is a bit noisy in this beetle but was good in the 1500 and I haven't finished the sound-proofing yet.
Nice set of videos - thanks so much for sharing - getting ready to do my first one. And this helps a lot.
Well you obviously know your way around a VW !every step done so smooth and deliberate ...not your first rodeo
Inspirational Sir, inspirational.
Yes the vw motors are ideal for all the reasons you list and when they started making beach buggys and off roaders in the 50's and 60's they were also cheap and readily available. The exhaust goes out the back bottom and the air comes in the top so keep them apart and no worries. Power output varies but wasn't a lot standard on these, I think the 1600 twin ports must be around 50 HP. You can't beat natural aspiration and a distributor-coil ignition for simplicity :)
Thanks for your answer. You are a true Gentleman.
Great series!! Thanks for posting the vids, very helpful.
Excelentes sus videos! saludos desde Lima Perú
wow!
i am from germany, 19 years old, and i love Beetles :))
and your rebuild o:
just awesome!!!
Excelente tarea de filmación y trabajo de taller. Muchas gracias por mostrarlo.
Thanks, it's a pity I didn't film the beetle rebuild too but it took 2 years for the car. Great wee cars these.
BEAUTIFUL VEHICLE WONDERFUL JOB CONGRATS !!!
Great Videos!! You make it look so easy. My 1600 engine broke a Cam yesterday. Would you recommend a total rebuild or a partial rebuild. The engine was rebuilt less than 4 years ago.
You make it look so simple!
Yes - it's actually called an "align" bore but everyone mispronounces it as "line bore" including me. They use a mill-type machine and run a specially made tool through the bolted up cases and take a few thousandths of an inch off the bearing surfaces. You can buy fractional oversize bearings to match. Best to go to someone who has done it before and has the special boring bar as there is no room for mistakes :)
That's going to be a messy rebuild - depending on where the cam shaft was you are going to have bent valves and punctured pistons so you should probably split the cases to get all the bits of metal out. While it is open check the crank shaft wear but if rebuilt 4 years ago should still be good if they did it then. New barrels and pistons would be the minimum. Good luck with the rebuild.
Yes stainless tubes - not sure if it's a good idea as they will be less flexible but they are working well and look nice forever unlike the rusty old steel one. Time will tell...
Hey mate, sweet vids. Just rebuild my 1600, put it in and upon start up all good, then engine noise changed and became internal and deeper, pulley started to move in and out and a bit off centered, then brown oil from the fly wheel area came out, pulled the engine and bell housing wet as, oil seal stuffed. Ideas of what happened? Gland nut was not that tight, what about too much endplay, the shims not correct? Help!!
@astro1218 Thanks, the fun - like building VW's and motorbikes - is in the making for me so it doesn't really matter :) Still nice to get good feedback every now and then.
Thanks, this motor probably came from your country :) Great cars & great motors
Great videos. Thanks for uploading!
muito bom amigo ...vc é fera.........estou aprendendo com vc ....
estou sempre vendo seus videos,parabens
Yes. It is not a high pressure connection but it should be small enough that it can be taken up with the paper gasket.
Olá Sou do Brasíl, tenho um Buggy e este seu vídeo de como fazer o motor é sensacional, grato pela boa vontade de produzir este material. :) Abraço.
Marcus Valdetaro
muy buen video!!!! gracias por compartir la experiencia !!
nice job guy
Great video's, Well done. Thank you.
Obrigado por seus comentários gentis
My machinist did skim the fly wheel when he did the line-bore and I had to adjust for it by adding shims. I have a video of it here somewhere showing how to set it up.
Just wonder, are there any vw engines for the beetle/bug (originally fitted) that has hydraulic lifters in them? Is it possible to do this to the ordinary engines that in the bug?
Just curious...
sweet videos!.. i wish this was for a pancake engine... i own a type 3 squareback 67 and im trying to learn everything from it... Thanks!
Great video ! I was thinking of using a 1600 engine in a buggy, could it work ? It Could be quite practical since the engine is using no electronics, no coolant (I think it is air-cooled right ?) and by being a "flat 4"it is low and in not cumbersome not heavy. however, something is bogging me : is the air intake and the exhaust in the same compartiment ? And also : approximately, how much hp is it producing ? is it a petrol or diesel ? sorry for bothering :)
Motor looks great, i see you added a few bolt ons, the car looks nice, RHD? Very collectible
What country
Thanks, yes RHD here in New Zealand.
parabens, gostei da montagem,sou mecanico diesel aqui do brasil,gostei muito.
May mate great vids! I'm Rebuilding my engine this week for the first time and was wondering how many hours it might take for a first timer to assemble and install, also if you had any tips for cleaning the case and what sealant to use. any advice would be awesome and again your videos were great :)
Why are the pushrod tubes so shiny, are they stainless?? i cant remember then being like that but it has been 40 years
Excellent
Great music as well, thank you...
Should the gap between the cylinder and head be uniform all the around?
Awesome job. thanks for the vid.
1600 dual port motor is the best like from a 1302 beetle. Twin carbs on top of the cylinder heads for best performance.
Haha yes it is a bit monotonous. It doesn't need the audio so just mute it I guess. You can't use anyone else's music these days without getting in trouble with the man so unfortunately it is just whatever I can knock up at the time. I'll try to tame it down a bit for the next one :)
Is a line bore a machinist sticks a drill through the center and cuts out any unround surfaces for the crankshaft to rotate on? What is involved? Thank you.
Can you give me advice which engine to use on a 500 pound dune buggy? Which air cooled engine do you suggest?? This engine you build?
this is AWESOME!!!!! ty so much
No just a good Bosch single vaccuum advance distributor. Electronic ignition must be better but it's not cheap :)
great job
muy bueno¡¡ gracias desde mexico city¡
are you running the Electronic Ignition conversion kit on your engine? if so did it improve your throttle resonance any?
have you looked on craigslist my friend?
See how much end-float it has by pulling the front pulley back and forward, 1/8" is a lot but if you barely feel it move then the bottom end is probably OK.Change the oil and clean the oil filter and then turn it over for a few minutes with the spark plug leads off. If it turns over smoothly connect the leads and try and start it. If it starts let it idle for five minutes and see how much crap comes out the exhaust. If it idles ok then set the tappets and test drive it. :)
@wiredkiwi i do the same to. you got some great videos im surprised they r not more popular.
Hey. Just wondering how you like that exhaust you have on there. I was think about putting that assembly on my 66' 1600cc.
Would you reccomend empi parts when building a performance engine? Great helpful video btw
hey sir, congratulations, your vids are amazing. Could you tell me why your vw 1600 bug have a differente song on the exhaust? Is a kind of explosion with air. Its a kind of whistle. How do you do it? near of 3:31 you can listen. thanks anyway :D
Hi dude! I would like to know, what is the model of exhaust you using in this beetle? Cheers
thanks!
The electronic ignition would improve the throttle response because with that, you are eliminating your points, condenser and vaccum therefore getting rid of the mechanic advance setup improving throttle response, i have the setup on my VW sandrail.
$50 is a bargain, and like you say, does away with the hassle later on. Down here VW stuff costs an arm and a leg :)
WOW Bravissimo!!!
Where did you get the spare parts from?
i am getting a 71 vw t2 for free with the engine not in the car. the guy giving it to me said he was told it was running when pulled, but that was years ago. so my question is would a full rebuild be necessary in my situation. or should i just put it back in and try it. and help would be appreciated
Yeah it's pretty strong down here, good climate I guess.
Yes but what's the worst that can happen? You can remove the engine yourself and strip it down. The only thing you need to farm out is the line bore if it needs one. If you are in the States the parts to do a full rebuild are so low even if you buy one of the rebuild kits. Just aim to make it stock or slightly warm and you can't go too far wrong and if it turns to custard you can always take the box of parts to a pro :) they will have seen it before.
Ahhh, memories...
Yes the later Kombis had bigger motors some air cooled some water cooled with hydraulic lifters.
thanks
sweet shorts bro
I use the Haynes repair manuals as my reference, they cover most of what you need to know- the rest is inspired guesswork :) Search Amazon for Haynes VW manual.
wow! it´s amazing how can you do that! thanks for the tutorial, i want rebuild my volkswagen!
nesesito que me puedas mandar un video de como quitar la bonba de aseite del motor conbi 1600
qual o torque que vc usa para fechar o motor?
Nice!!!
I want to learn this job
Yeah I know it must be weird shifting with your right hand. Two-thirds of the world drive on the right now so it is probably about time they standardised it :)
@astro1218 Yeah it always does. I make it then start working on my beetle and forget to drink it. Half the time I drink it stone cold :)
your coffee is going cold man :P
Obrigado, eu gosto de fazê-los :)
grasias por el video tengo que aprender aserlo yo solo con motor de conbi 1600
Very nice. :)
cual es el torque de las camisas o cilindros y la culata
ho dios mis respetos para este señor lo diere asi es un cabronaso de la mecanica muy bueno demaciado