Sallittjob's 1968cc Build

[email protected] · Posted: Mon Aug 04, 2014 9:53 am Post subject:

post a picture of the seals, cooler, and case you are using, so we can view possible errors. Wrong seals is a common and easy mistake to make.
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sallittjob · Posted: Sat Aug 09, 2014 9:34 am Post subject:

I finally got around to taking some picture of the oil cooler seals in question. The new cooler is mounted to the engine so I took a picture of the old case which has the same sized oil galleries. The new case is an AK AS21 case the old case was the original AE AS41. Also, I took a picture of the seal that I used in all four places. I took a picture of the old oil cooler where you can clearly see no bosses present. In the third to last picture of the new one (mounted) you can see the boss on the bottom of the cooler.

Image may have been reduced in size. Click image to view fullscreen.

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57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

[email protected] · Posted: Sat Aug 09, 2014 9:37 am Post subject:

The seals look correct, but you are missing your Hoover Bit.
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It's just advice, do whatever you want with it!

Please do NOT send me Private Messages through the Samba PM System (I will not see them). Send me an e-mail to john at aircooled dot net

"Like" our Facebook page at
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and get a 5% off code for use on one order for VW Parts ON OUR PARTS STORE WEBSITE, vwparts.aircooled.net

75smith · Posted: Sat Aug 09, 2014 1:56 pm Post subject:

seals do look correct, I would expect the seals to compress a little, and that the cooler not actually contact the mount-because then all the pressure is on the bosses, not the seals-that would cause a leak

just double check you did 60in-lbs, not 80in-lbs and call it good
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My 1975 Beetle Build Updated 8-21-12

My engine build

sallittjob · Posted: Sun Aug 10, 2014 4:08 pm Post subject:

Sounds good, hoover bit is on order.
Thanks Guys
_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

sallittjob · Posted: Mon Oct 20, 2014 7:30 pm Post subject:

Hey guys so I have a problem.... I've got everything back together and I'm trying to prime the oil system before attempting to start the motor for the first time. I have a full flow system installed with a cast iron 26mm pump set at zero lash. I pack some petroleum jelly inside the pump prior to assembly. I removed the inlet line to the oil filter adapter and cranked the engine about 5 times and didn't get a drop of oil out the line. Next I poured some oil down the line (output of the pump) and tried again a couple times...No dice. Finally I removed the outlet fitting from the pump and had my buddy hit the starter while I looked. I saw the PJ move out a little after a couple bursts but no oil.

I gave up for the night but now I don't know what to do next. I'm almost positive the pickup tube isn't hitting the screen (I took the plate off yesterday and it had a good amount of clearance (running a deep sump).

I can't get the cover plate off the pump as the crank pulley tin is in the way. I was thinking of trying to hand crank the engine in reverse while feeding oil down the pump outlet line. Is this a good idea?

Any help would be greatly appreciated.
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57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

ALB · Posted: Mon Oct 20, 2014 8:09 pm Post subject:

You've got jelly creating a seal at the gears and air in the intake tube before the pump. I would do what you're thinking; hand crank it in reverse while feeding oil down the flull-flow tube until you hear the "burp" of air clearing the intake tube and then turning it over clockwise until oil pushes out of the line so you're sure the pump is primed).
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On a lifelong mission to prove (much to my wife's dismay) that Immaturity is Forever!!

sallittjob · Posted: Tue Oct 21, 2014 7:11 pm Post subject:

Success! I removed the AN fitting from the outlet of the pump and threaded an NPT barb in it's place. Ran a piece of rubber hose and shoved a reducer attachment on my shopvac into the hose. I turned the vacuum on and let it pull for a minute or so (did this twice). Second time around I saw a few drops of oil come out the hose. I disconnected the fitting and spun the crank by hand and oil poured out!. Pulled the pressure sensor and cranked the engine until oil spurted out.

One problem down...So next I hooked up the fuel pump (mechanical) and cranked it a little more to fill the carbs. What do you know the pump leaks fuel so I had to stop again. I'm going to try and get a new pump tomorrow and hopefully post a video of it running shortly after.

Thanks everybody for the help!
_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

sallittjob · Posted: Wed Oct 22, 2014 7:20 pm Post subject:

Wanted to share a couple progress pics from my build. Hopefully I can start it for the first time tomorrow night. Thanks to everyone who's contributed to my threads for sharing your knowledge. I've been dreaming about building this motor for several years and I couldn't have done it without this forum and it's contributors.

_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

RHough · Posted: Wed Oct 22, 2014 9:06 pm Post subject:

sallittjob · Posted: Thu Oct 23, 2014 7:15 am Post subject:

RHough · Posted: Thu Oct 23, 2014 12:33 pm Post subject:

sallittjob · Posted: Fri Oct 24, 2014 9:44 am Post subject:

The venturis are removable so there are several sizes which could be installed on a set of DRLAs. I don't remember what size mine were off the top of my head, I'll take a look in my notebook and post back with that info later.
_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

sallittjob · Posted: Fri Nov 07, 2014 3:42 pm Post subject:

Hey guys, I need HELP getting this thing running right.

I've been chasing what I think is a manifold leak for over a week now. I must have taken the manifold/carb off the engine and reinstalled five times now. Basically when it idles (DLRA 40s, 34mm vents, 60/140/180) it wants to die unless I give it gas. When I spray carb cleaner at the base of the 3/4 manifold the engine speed increases a good amount.

I ordered new fiber gaskets from aircooled.net and used a dremel to match them to the manifolds. Also, I checked the manifolds with a granite surface plate at work and lapped them perfectly flat. They aren't hitting the tins, and the gaskets lay perfectly flat. I tightened them down and it still leaks.

I hooked up the wideband and it says I'm idling around 19:1 AFR. The weird thing is the idle speed increases the most when I back out the mixture screws fully on the 1/2 side and screw them almost all the way in on the 3/4 side... I'd think if I had a vacuum leak on the 3/4 side I'd need a richer mixture on that side and leaner on the other, right?

Please help me out here, I have no idea why the manifold won't seal and this is driving me nuts.
_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

[email protected] · Posted: Fri Nov 07, 2014 3:48 pm Post subject:

Are you sure the center section isn't bottoming out on the end casting?

To be sure, install the intake with the intake boots OFF. Make sure the center section can float a little bit.
_________________
It's just advice, do whatever you want with it!

Please do NOT send me Private Messages through the Samba PM System (I will not see them). Send me an e-mail to john at aircooled dot net

"Like" our Facebook page at
http://www.facebook.com/vwpartsaircoolednet
and get a 5% off code for use on one order for VW Parts ON OUR PARTS STORE WEBSITE, vwparts.aircooled.net

jfats808 · Posted: Fri Nov 07, 2014 4:01 pm Post subject:

Dykem your intake port base and mount your manifolds alone on it. Tighten it
down and wait a few min. While youre waiting pull your idle jets and check they arent clogged. It feels like something simple.
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2276 IDA's 86C 11-1 DD !
2017 48 Trijet DRLA's W125

sallittjob · Posted: Fri Nov 07, 2014 4:06 pm Post subject:

RHough · Posted: Fri Nov 07, 2014 4:10 pm Post subject:

sallittjob · Posted: Fri Nov 07, 2014 4:13 pm Post subject:

Gotcha. Yeah I'm running dual DRLA 40s.
_________________
57' Beetle Deluxe
1192cc SP

71' Super Beetle
1968cc DP

73' 412 Sedan
1679cc FI

75' Westy
1800cc FI

jfats808 · Posted: Fri Nov 07, 2014 4:15 pm Post subject:

Just for kicks, make sure theres a clean hole thru. Magnifying glass or up in the light. Drlas are a different animal. Seems they do like a bigger baseline jet then webers. Generally I use the 1.5 modifier for idle sizing for break in/initial. Then I dial down or up as the engine requires it during the testing portion in the vehicle amd under load. Sometimes I have to hand drill what the engine wants.
_________________
2276 IDA's 86C 11-1 DD !
2017 48 Trijet DRLA's W125


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