HOT 1915cc VW Engine Tear Down After 90 Miles! Sneak Peak At A New Aluminum Case!
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- เผยแพร่เมื่อ 7 ม.ค. 2020
- Tearing down the new 1915cc Volkswagen engine for my 1973 bug. It has 90 miles on it and I’m not happy with a noise that I’m hearing from inside. Let’s dig in and see what’s going on!
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CIP1 rans some great deals over the holidays, almost pulled the trigger on some parts, who does not like buying vw parts. But i knew with this foot going to the hospital every week for 8 months i will be a while before i'm buying any parts, but still have my foot life is good.
Busman 54 they definitely did have some great deals. I hated to spend the money and honestly I didn’t have it to spend but such is life sometimes.
Hopefully soon the foot issue will be a distant memory for you.
Ill def be watching @ work
Hey Jawbreaker,
I'd get a quality inside micrometer, torque up you nrw case halves with nothing inside and check your bearing tunnels are not "out of round". Weve had to line bore brand new unused cases (both new VW factory made and Autolinea) before because bearing tunnels were out of round. Also, check the two case halve mating faces are perfectly flat / straight within tolerance. Its the old story now days - don't trust anyone elses machining work and check measure everything. We found the accuracy of the machine work on those Ali bubble cases not as accurate as the new genuine vw factory cases. However, we don't mine redoing the odd bit of machining if require as there's a lot good things done for the price in those bubble cases :)
Mathew Boyd excellent advise, thank you for that info!
I actually did just that to ensure the inside measurements were correct with my telescoping micrometer and calibration tools. Definitely didn’t want to trust a new case after this fiasco.
I appreciate you taking the time to comment and provide your input!!
@@VWJawbreaker
It's interesting that your old case was machined too big in the tunnels. Because that tells me your machine shop recently adjust the cutters and were sloppy when checking the accuracy when lineboring an old dummy case afterwards. Not only that, they should have checked your case afterwards too! I would definitely let them know they got it wrong on your old case so they know to reset their cutters (again). As their cutters wear the lineborer tends to cut smaller holes, not larger so they must have messed with it recently.
Mathew Boyd yes sir, I reached out to them and let them know what happened. Later next week I’m taking it over to them for them to reinspect, figured if it helps the next person out it’ll be worth the little extra effort on my part.
I love my aluminum bubble top case that I used to build my 2 liter. HOWEVER, I did find a problem with the oil hole that feeds the main bearing was slightly out of alignment. To correct this I slightly enlarged the oil hole in the block with a dremmel tool to better center the flow to the main bearing. (Very small amount) The problem was only on one bearing and it was common on the early aluminum cases. Probably not a big deal on the new cases but please check yours. I also forgot to put sealer on that oil galley plug behind the flywheel. It was in tight but leaked slightly after I had it in the car. Have fun with your new build and Happy New Year my friend.
TheEZGZ happy new year buddy, hope you’re doing well!
I did find that a few of the oil holes didn’t line up with the bearings, I did mod those during the bottom end mock up. I added blue lock tight to the rear galley plug to keep it tight and from leaking. Also, blue will allow me to remove it later on down the road when needed.
I appreciate your input, videos and comments, we’ve all learned quite a bit from you over the years. I’m just trying to give back and hopefully help someone along the way.
Good Video. Bummer about the bad machine work on the case. About a minute in your last video you mentioned about the first fit of the bearings and that it felt odd to you. Then when you had talked to your machinist about it they said it sould be fine was a horrible thing to hear. I feel like the machine shop owes you a case, bearings, and a whole bunch of free shop labor along with an apology. You should have been asked to bring it in immediately so they could check for a mistake on their part. Either incorrect machine work or bearing set. Your own spider sence questioned it... So smart of you to pull it when you did, you saved it from catastrophe! You live and learn, and we who watch do as well. Keep at it good job and thank you for the videos.
Rob Sannes you’re absolutely right about all of it. I wish I would have listened to myself more but we all learn from mistakes. I try to be transparent, I don’t hide anything, what you see if what you get with me. If I mess up then you’ll see it. I was honestly really bummed to the point that I didn’t want to record any videos but then I realized no one else would learn anything. Seems everyone is seeing things slightly different and that’s ok with me. We all learn at different rates and see things differently.
Thank you for following along and for your support through this.
I liked my Auto Lina case...but......the tin didn't fit right ( I had to trim it) , and I had a hell of a time trying to find a generator belt because the case was too tall and placed the generator a little higher. Really nicely made though and great for hot rod applications. lot of great upgrades.
OkFixer you are absolutely correct! It does take some work to get the tins to fit right!
Man sucks you had 2 pull it down! The new case looks sweet! Can’t wait 2 see it go back together!
Mileage Unknown yeah, better to pull it down now vs later with possible damage. Those new aluminum cases are pretty sweet.
Now I'm jealous!!
That aluminum case looks real sweet!!
I think I know where this is going!!
Keep up the great work brother!!
VeeDub P8 yea sir, the aluminum case was the ticket! Money well spent that I didn’t have 🤷♂️
New video tomorrow morning, trying one a week for a while, getting tired and too much going on for more.
Congratulations on the new case. Looking forward to the next episode
Jonathan Hicks I’m not sure if a congratulations is needed, my credit card says otherwise 😂
Videos will be out every Wednesday, thank you for watching and commenting.
Thanks for the info.
WoW, 90 miles.
Volkswagenplanet yep 😔
That new engine block looks awesome. This will a nice build with this new case. Looking forward to watching the build. Thanks Much Buddy and keep VeeDub’n . BigW:-)
Big W Adventures hopefully I’ll have better luck this time. Wishing you both a wonderful rest of the week!
Hey Gary that's a new one, i've seen plenty of pinched bearings, but never seen a wobbler like thay, that's to bad , now i get to see you put it together in the new case
What’s so odd is that it didn’t wobble when I put the engine together…. Had a fresh lime bore. Oh well, life happens!
Looks like the cutter for the line bore was set a little to large, O well at least you can make it bigger and better 😉. I will take that case if you are not going to use it😉
Matt Lundquist yes sir, I let my machine guy know what happened that way he can verify his cutters.
As for the case I haven’t decided what I’m going to do with it just yet.
@@VWJawbreaker if it were me I would take it to another shop and get it cut one more size up. Make sure they will measure the bearing o.d. before they cut. Space coast imports in Melbourne 1321-409-8989 has cut cases for larger bore and done a great job , I think they can do line bore also.
Matt Lundquist thanks, I’ll look into them. For now the case is just sitting in the garage until I decide what I want to do with it. Might end up selling it to recoup some.
That's a sweet case man! Very nice! =) Sorry about the old one.... Great video!
CT thanks man,
Things happen and we just have to push forward. Hope you’re feeling better.
I built these motors for about 50 years, that bearing didn't spin in the case, if it did, IT WOULD HAVE BEEN A MESS when you split the case.I could tell by the play of the bearing in the case that either the line bore job was screwed up or the bearings were the wrong size. When you have somewhere near a correct fit you can GENTLY press the bearing into it's seat with a finger or too. I bought a line boring machine in 1980 and line bored dozens of engines. Checked every on with a dial bore gauge before building or shipping a case.
I was trying not to railroad the guy who worked my case. The bearing was slightly snug with no play when I mocked up the engine and the assembled the engine.
It could have been an issue with the case as well..... things happen unfortunately.
@@VWJawbreaker It's not a case issue, it's either a line-bore issue or the wrong bearings. Outsourcing work can be a pain, there was a guy in my area lineboring cases and I fixed several of his that were screwed up. Rebuilt connecting rods I got from an import store were frequently bad, I returned 1/2 the sets they sold me. In 1984 I finally bought a Bridgeport mill so I could rebuild rods inhouse and I knew they were right. I could also bore blocks and cut heads with it, excellent machine.I would make bus 1.7 heads into 2.0 litre heads with it too.
Good gawd I’m nervous now! Building or buying an engine this spring. I have an original mag case in my bug now that has never been rebuilt, but the rings are gone. May still just do a top end if the bottom still feels good... also contemplating building with a new AS41 and just having a new, durable, solid 1641.
Misunderstoodboygenius if your end okay is good and if the side to side play in your rods are ok and there isn’t an oil pressure problem I’d just do a top end rebuild and keep buggin along!
Loving your videos. I just pulled my first aircooled motor last week. Purchased a 72 SB for my wife, knowing nothing about them. Now Im hooked. Cant wait to get this motor rebuilt and running!
I appreciate you being here and thanks for taking the time to comment! Feel free to ask questions and there’s other great people in the description of the video who also have a lot of knowledge, make sure you check them out also.
Congrats on the new family addition and the new addiction lol
@@VWJawbreaker thanks for your input. I'm wondering also if hydraulic lifter conversions have been used on stock 1600 cases.
@@tomstulc9143 I haven’t researched much of that.
@@VWJawbreaker I am sorry that I never saw your response. I appreciate you taking the time to do so. I ended up having to buy another motor as this one had 2 cracked pistons and the case was junk as well. Picked up a used 1641 and learned the hard way to trust my gut when I meet someone who seems sketchy, that motor ended up having major issues, I am currently rebuilding the heads as 2 of the guides were bad and my oil looked like gold spray-paint. Getting ready to crack the case and try my hand at a rebuild. Found an old 1600 to throw in the SB for now so I may have to fin another VW for this motor when I am finished with it! As always, love your videos. You recent Baja videos have turned my attention towards wanting to pick one up.
shit happens man. stay positive and keep rolling with the great videos! Man I've been thinking of grabbing one of those cases and your making me wanna pull the trigger.
Vdub618 thanks, the positive power from everyone is helping me push forward, I greatly appreciate it.
The aluminum case is definitely nice. I’ve heard mixed reviews but after receiving it I really don’t see any negatives. Take your time and look things over to ensure everything is correct and make any small adjustments you need.
Nice case brother!! Very cool!
JW Classic VW my credit card thanks me also 😂
I purchased a used crank with rods. They had standard mains on a 10 10 crank. 12 thousands clearance. If your mains were wrong cut for the case? Hard to spin with dowl and correct bearing. Use center main to make sure all the main dowls are aligned and crank is all the way down. Nice new case I'm jealous.
I’d double check your main bearing clearance especially if they are silver line brand…. They have been known to be off here and there.
“Victory comes from finding opportunities in problems” - Sun Tzu
Thank you for your commitment and the vid. Much appreciated!
Bombero Bus thank you for your comment and for hanging around, that is much appreciated!
Interesting unboxing. I have mixed views on these new aluminum cases, bit I do see where you are going, and I think I know what is in the other box. On this next engine build just make sure you add a deep oil sump to the mix. It will definitely help keep things cooler.
masbeetleboy I’ve read and heard mixed reviews about the aluminum cases as well, figured for the price I couldn’t beat it. I personally think some of the hype is due to people not wanting to move away from the magnesium cases like VW made. However VW hasn’t made a case in a long while and these old cases are getting really worn out.
I hear you, but I think you can still get them new. For what I think you want to build however, that aluminum case will be fine.
Have fun with your build 🍻
Marc Fisher thank you. there’s plenty more vids, I have had a lot of fun with the build. Thanks for being here.
That’s a bummer what happened, that’s why I don’t trust reusing old engine blocks. You made a smart move, especially with an aluminum case!!! Looking forward to the progress for sure. It’s sad that it had to go this direction though. It definitely was not your fault. I think some of these old engine blocks are just tired. That sure is a sexy case, I’ll be watching closely CIP1 is who I’m going to start using. For various reasons. Great job Gary!
Slades VW Beetle it is a bummer, that’s for sure. My channel is about learning and growing together, we all make mistakes and things don’t always go right. This time things didn’t go as planned, but I must pick up and move on. Just sharing my experience with others so hopefully they learn as well.
VWJawbreaker Absolutely!! It is about growing together as a community and learning. I wished things like that didn’t happen, but they do. You really did pick up and move forward! And kept a smile! 👍🏻🍺🍺
Slades VW Beetle it took a lot for me to hit the record button and put a smile on my face.
@@VWJawbreaker i am sure it did my friend! I can understand!
i like the shop stool with the flames! you've got a crank in that other box don't you?
Scotty C maybe 😂
I miss my 1915 I built for my 64 .I worked at cb performance put cnc 044 heads with 44x37 valves match ported manifolds dual 48 dellortos ,custom grind cam header with custom flowmast 40 exhaust,electronic ignition pro street trans was fast as shit lol prob 12:90 1/4 car
Yes sir, build them right and they are a ton of fun!
love the details and pointing out some the NOT so obvious signs of BADNESS to the Newbies in the VW world!. Great visual and spoken details!!!!
+DeeLyriuz I appreciate the kind words and thank you for being here.
I’ll be watching soon as I get up!
Vintage Bugz I was honestly still up. My damn pc took a crap and I had to reformat. Then I seen jawbreaker video!!! 👍🏻👍🏻😃😃
Vintage Bugz Thanks, it’s back up now but a ton of crap to put back in. 🙄
Thank's again.
Thank you for being here.
Where I could find out about racing I m looking for one that starts making power around 1500 rpms where is your opinion about web cams .
I don’t have much experience with web cams but I hear great things from people who do run them.
Not sure what kind of racing you’re referring to. There are a few cams that come in around 1500 rpm, kind of depends on your brand preference.
I just got the same case, I cant wait for the rest of my parts to come!
Just inspect it to make sure it’s ready for the build. Do not assume because it is new that it is perfect.
Enjoy your build!
@@VWJawbreaker Will do! I'm watching as many videos as I can. Did you use an aluminum pully with the aluminum case?
@@edweigman9683 I think I used a steel one to begin with but I’m using an aluminum one now without any issues.
@@VWJawbreaker good to know! I'm still debating on straight cut gears or helical, I have both.
@@edweigman9683 straight cut are only needed fir high lift cam / ratio rocker combos....
Unless you like the sound of them 😁👍
Wow. That's a harsh find after splitting the case. The new case looks amazing! Do you have a part number so I can check the specs through CIP1? I'll enjoy watching the build. Thank you Jawbreaker!
Jim Lester yes sir, it sucked to have to do this but it was the smartest thing I could have done. You should never ignore something you feel is not right.
The part number is C13-98-0454-B. Definitely a good case and I know a few others who are running them with great success. Thanks for your support and wish you a great rest of the week!
Hate to see this kinda stuff happen hope the new case sorts all your issues out. Enjoying all the content and pointed someone to one of you old videos the other day.I hope to do a similar engine build in the future.Would you happen to have that cip1 part number on the case you got? Thanks again for all the info.
transam197781 it really bummed me out but such is life.
thecase I purchased is : C13-98-0454-B - EMPI HEAVY DUTY BUBBLE TOP ALUMINUM ENGINE CASE.
I appreciate you recommending my vids to others!
Are you going to replace the oil pick up tube in the new case?
Vintage 76 vipergreen # Romeo I hadn’t considered it, I measured the new pick up tube in the case vs what was in the stock case.... seemed fine to me.
Im in 1915 Hell (69x94)....After getting my 1915 built by a sketchy shop (Dons Bus Box/ Donson Performance) I hate it. Its finally running pretty good thanks to another shop, BUT will not Rev above 4500rpm (seems like floating valves) They believe its the heads. I got Kultech Outlaw heads and evidently, their basically stock heads with big valves. I may just start all over even thou this was a pretty penny spent. Thoughts?
Dang man, sorry to hear about the issues you’ve been having.
Did the heads you bought come with HD valve springs?
What cam does the engine have?
Do you know the compression ratio of the engine?
Having this info would help me better answer you.
You got lucky. I got my aluminum case from CB and it was a disaster. I swear by them. My 2 liter is my best engine
I remember that fiasco you went through. Seems like you lost motivation after all of that. I learned a lot from you showing us what all you found.
Thanks for the update, sorry it meant a pricey redo but you're back better than before! Was there not enough crush to hold the bearings? I was actually looking for that spec the other day...
Haptic Garage the main bearings shouldn’t crush, just fit snugly into the case. Basically put the bearings into the case by themselves, align the dowl pin and they should snugly go into place. Not loose and definitely not super tight.
@@VWJawbreaker Makes sense. I've been playing with an old case and some measurement tools. These things can be tricky, but what a fascinating engine design. I'm glad yours is one the way to awesomeness!
@@VWJawbreaker Just found that spec- says the bearings should be 0.0015" to 0.002" bigger than the saddle. I'm pretty sure that's an egghead's way of saying "snug". Thanks again for the clear explanation!
Haptic Garage that sounds about right, I wasn’t sure if the spec myself as I can’t keep all of that info in my head. I have cheat sheets at home 😁
Egghead’s... man that made me laugh!
Thanks for the vid 👏👏
Did you get an oil pressure measurement prior to removal?
Oil pressure was good, 20-25lbs at warm idle if I remember correctly.
Dowel "jumped out" ? where did it have to go?, looks like the crank weights were in contact with the case.
The dowel didn’t jump out. Nothing was in contact with anything. Ended up being an issue with the line bore that didn’t show up at first.
You are going to Premiere a video at 4:45 AM?
VW Life 5:45 eastern time.
Was the old face lined bored
I know whats in the other box 😁🙊
Im loving that new case, it looks soo sweet
VW RICH FLAT4 it is a sweet case and I figured you’d know what was in the other box 😁
Hated to spend the money but I’m tired of dealing with old cases and having problems.
@@VWJawbreaker im with ya.. Im hoping my stock case stays in good shape till i can upgrade $$ lol.
My temporary plan is some 87 p/c and better carbs...or carb 😋
VW RICH FLAT4 87mm p/c set, get your stock heads ported and a small cam update with exhaust and carb will make a nice difference!
@@VWJawbreaker yesss.. All in due time 👍
@@VWJawbreaker i got my fuel pump back working again.. The previous owner installed a hidden kill switch..it's wired into a relay and piggy backs off the factory power wire to the pump.. I just bypassed the relay, connected the pump to a good fuse location and vroommm.. Started up 🎉
That just made my day 😁
Do you think the case just could not handle the HP or what would have caused it to do that. It was tight when you put it together.
2 Guys and a Bug I’m not 100% certain what caused it and yes, they were not that loose when I mocked up and final assembled the engine. I doubt it was a hp issue, I never really ran the snot out of it since it was so new. I’ll run them, get on it a little here and there but won’t beat the snot out of it until it has more Milage on them.
@@VWJawbreaker That is strange but going with a new case and what ever else is in the box :) will be fun to watch as you put it together.
What are you running at that T in the oil line right near the filter? (And yeah, CIP1's holiday sales are pretty much where I end up bulk buying parts every year. I can't reason paying more at other sites for the same stuff unless I absolutely need it!)
Toddmichael Janiszewski i try to buy local as much as I can but I have a small budget most of the time. Gotta save where I can.
The T in the oil line by the filter is the oil temperature sender.
@@VWJawbreaker I may have to consider that location for my future engine. I was going to tap the Type 3 oil cover plate.
Toddmichael Janiszewski i thought its that location as well but wanted to see what the temps were while the oil was flowing vs moving around inside the case. Just my $.02 anyway.
@@VWJawbreaker Yeah. Definitely something for me to consider for future build.
what was the noise you heard to know this was an issue?
VW Life there was a loud clicking noise coming from the engine that sounded different than an out of adjustment valve. I used a long screwdriver as a stethoscope to narrow down the sound and it appeared to be coming from the nose. There wasn’t much difference in the noise with or without the crank pulley on.
Your experience and many others I’ve seen are making a strong case (pun intended) for not trusting a 50 year old soft magnesium case for anything more than a vintage restoration that wont see many miles. When building a hot motor I’ll definitely be looking into an aluminum case first.
Patrick S they do sell new magnesium cases but I figured with the potential for going bigger later the aluminum case better suit my needs. Plus I did like how the aluminum case main studs are shuffle pinned and that helps prevent the case half’s from moving back and forth.
I'm rather shocked it came with the nuts and washers! I plan on using the 94mm cut version of this for my next engine build.
Toddmichael Janiszewski it came with everything minus the oil relief and bypass plungers, springs and caps. You’ll also need the 2 engine mounting studs to mount the engine to the trans. If you have an old case you’re replacing, you’ll have those items.
@@VWJawbreakerI have about 4 old disassembled engines now. So much tin to restore!
The plan right now is to do this as a 2276 with a Gen4EFI setup. Basically trying to build a solid reliable more modern powered engine for the future restomod 72 1302 German Looker I'm building.
Toddmichael Janiszewski man that would be an awesome build. Are you going to record it??
@@VWJawbreaker Probably. I document everything but I'm not really like you in terms of production. All my stuff (and car pages) are here at my site zuczek1302.com/ I'm just an amateur late comer to actual auto mechanics, but the project manager in my makes me document everything in text and photos.
@@VWJawbreaker Honestly, I'll just be happy for warmer weather to return so I can get my 1600 Plus new build running and broken in on my 72 and then the long term disassembly of the car for restoration. I have to do a lot of work on my 79 Beetle's engine as well. It is a total survivor car and the 41 year old fuel lines and o-rings on the FI went a few months back. So much work ahead of me.
Well that would make some noises from within...
Vintage Speed VW just a tad I found out. The other noises must be the steel straight cut gears.
@@VWJawbreaker ya they make alot of noise for sure.
Vintage Speed VW need to pick your brain regarding tuning sometime in the near future. Hope you’re doing well and your project is coming along well.
@@VWJawbreaker no problem.
Was the old case align-bored? If fitted with new bearings matching the rebore and crank there's no way it should have spun like that. Crazy.
Yes I hear ya. It was aligned bored and new bearings matched the bore.... this was a new one for me, haven’t seen this issue before.
@@VWJawbreaker Makes me a bit nervous: My block is in for align-boring at the moment...!!
Martin Harris I’m sure you’ll be ok. I rebuilt plenty of others with aligned bored cases and didn’t have an issue. I think there was an underlying issue with this used case I wasn’t aware of.
I'm lost. How is the case bad. Spun bearing damaged a case?
Volkswagenplanet the case needs to be line bored again, but that wouldn’t make it live a long life with this hp. A case can be cut 4 times, each time it takes .020” off. Max is .080”. This case would end up being .060” over if I had it cut again.
@@VWJawbreaker
I would cut the case again, and build a stock engine as a, plan B engine on standby.
Vintage 76 vipergreen # Romeo not a bad idea. 👍
What’s up with the dist gear ?????
Not sure, I replaced it.
Was the old case line bored ?
It was, we later learned there was an issue with the cutters he used.
@@VWJawbreaker yeah no good ,I may also just purchase a aluminium case also.
@@VWJawbreaker year no good . It’s hard to find good help
@@harryloibl5183 hard to find good parts also.
How much is that case ?
About half of what it costs today…. This was 3 years ago.
Dude! You need to lay off the N2O. 🤣
Keeps ya on your toes 😂
Why is the case painted?
A light coat of paint doesn’t hurt them.
@@VWJawbreaker Thank you for the answer. Not sure if its true or a load of bull stories was told if a case gets painted it'll warp or distort from heat. All my cases ive kept like it came out of the factory did polish one up too nake it stand out when engine was shown.
I’ve heard the same thing regarding painted cases. On the flip side I know several people down here in Florida that run painted cases without issues. Trick is a thin dust coat of paint, not layers of primer and multiple coats of paint.
@@VWJawbreaker i live in south africa it gets warm here at times. My last engin case gave it a good scotch brite clean ended up with a semi polished case.
I’m in Florida and it was 107 with the heat index today, haven’t had issues with painted cases here.
I’m sure the semi polished case looked pretty good!
Didn't see the cost $$$$
Cost fluctuates with time… especially now a days.
So does anyone know if there is a way to open the cylinder case for bigger barells while in place . I have a new set of 92 barells an forged Pistons. It was a 200 dollar package deal. three engines complete in addition new reground crank new zenith carb prop hubs etc.. An inexperienced avaitor crashed his on the first take off an sold me all his stuff cheap. experiment airplane builder. I robbed the stock 1600 top end for my airplane but would like to open the case up for the 92s.
@@tomstulc9143 you’ll need to split the case for them to open up the cylinder holes. Plus you’d want to clean out all of the debris from the machine work before running the engine.
@@VWJawbreaker unfortunately. Was hoping some one pioneered an ulturnitive procedure.
@@tomstulc9143 completely understand.
1 second ago
A 13 minute video and you waste the first 20% of the time marveling about cardboard boxes and sandals. I could see where this was going and lost interest.
To each their own dude. Happy that you stopped by. There’s plenty of videos out there, go find one you like.