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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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 Posted: Wed Aug 13, 2025 5:19 pm Post subject: Engine build parts list? |
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Anyone have an itemized parts list for an engine build? I've never built one before, so I'm trying to organize parts, prices, and vendors instead of randomly buying things willy nilly.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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Glenn 
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Wed Aug 13, 2025 5:40 pm Post subject: Re: Engine build parts list? |
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| Glenn wrote: |
Buying individual parts from various vendors is for the experienced builder.
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..apparently it's also for the inherently wealthy.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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| Posted: Wed Aug 13, 2025 5:47 pm Post subject: Re: Engine build parts list? |
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| CoastalBug wrote: |
| Glenn wrote: |
Buying individual parts from various vendors is for the experienced builder.
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..apparently it's also for the inherently wealthy. |
You get what you pay for.
You can also delete things, like if you have a case. You can also replace parts.
Or you can buy parts from AA and CIP and JBugs and roll the dice.
Or buy a already built longblock for $4000.
https://gex.com/collections/rebuilt-performance-longblock-engines
Good parts are not cheap... cheap parts are not good.
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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| Posted: Wed Aug 13, 2025 5:53 pm Post subject: Re: Engine build parts list? |
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BTW, what are you looking to build?
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Wed Aug 13, 2025 5:55 pm Post subject: Re: Engine build parts list? |
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| Glenn wrote: |
| BTW, what are you looking to build? |
A 1776. I have a running 1600 DR/SP, so I have a lot of the parts already. I'm just looking to put things on paper and weigh options as to whether I build a whole new engine, or just rebuild mine.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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| Posted: Wed Aug 13, 2025 6:02 pm Post subject: Re: Engine build parts list? |
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Buy a set of AA 90.5 p/c, have your case cut, your heads cut and ported and add a set of dual 40mm Solex carbs.
A performance cam and counter weighted crank are nice upgrades.
Add bearings and a gasket set and reuse everything from your existing engine.
Want more.... better heads, dual IDFs and hot cam... just costs $$$$.
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Wed Aug 13, 2025 6:05 pm Post subject: Re: Engine build parts list? |
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| Glenn wrote: |
| have your case cut |
That's what I'm trying to avoid if possible. Multiple machinists have said that for every 5 cases they get in, only one is suitable for rebuild. I'd rather keep this one running until it completely dies.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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| Posted: Wed Aug 13, 2025 6:17 pm Post subject: Re: Engine build parts list? |
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Case
main bearing dowels
main bearings
rod bearings
cam bearings
crankshaft
crank build up - cam gear, spacer, distributor gear, snap ring, oil slinger, woofruff key
connecting rods
camshaft
lifters
distributor driveshaft and 2 thrust washers
pistons with rings
wrist pins with 2 snap rings
cylinders
fuel pump pedestal and pushrod
heads with valves, springs and retainers
pushrods
case hardware, nuts, washers and studs
gasket set
flywheel seal
endplay shims
flywheel
pressure plate, disc and bolts
oil pump and cover
oil strainer and cover plate
oil cooler bypass piston, spring and plug
oil pressure control piston, spring and plug
crank pulley
alternator stand
valve covers and bails
alternator with 2 woodruf keys
alternator pulley and shims
fan, fan hub, shims
distributor
all sheetmetal including fan shroud.. etc.
carbs with intake manifolds and linkage
Exhaust / muffler
I think that's almost everything
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
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RickS
Samba Member
Joined: May 05, 2005
Posts: 610
Location: Speonk, NY
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| Posted: Wed Aug 13, 2025 6:18 pm Post subject: Re: Engine build parts list? |
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| CoastalBug wrote: |
| Glenn wrote: |
| have your case cut |
That's what I'm trying to avoid if possible. Multiple machinists have said that for every 5 cases they get in, only one is suitable for rebuild. I'd rather keep this one running until it completely dies. |
You can’t build a 1776 without cutting the case. |
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Glenn
Mr. 010
Joined: December 25, 2001
Posts: 79795
Location: Sneaking up behind you
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| Posted: Wed Aug 13, 2025 6:23 pm Post subject: Re: Engine build parts list? |
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| RickS wrote: |
| CoastalBug wrote: |
| Glenn wrote: |
| have your case cut |
That's what I'm trying to avoid if possible. Multiple machinists have said that for every 5 cases they get in, only one is suitable for rebuild. I'd rather keep this one running until it completely dies. |
You can’t build a 1776 without cutting the case. |
You're looking at $1500 for a new EMPI magnesium case already cut for 90.5.
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Wed Aug 13, 2025 6:50 pm Post subject: Re: Engine build parts list? |
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| RickS wrote: |
You can’t build a 1776 without cutting the case. |
Yes I know that. I'm trying to avoid cutting *MY* case since it's a running engine. We have a swap meet coming up this weekend and I'll be looking for cases, and one of our local club guys who has a machine shop believes he may have a suitable used case for me.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Wed Aug 13, 2025 6:50 pm Post subject: Re: Engine build parts list? |
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| Glenn wrote: |
You're looking at $1500 for a new EMPI magnesium case already cut for 90.5. |
See my response above.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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Murt
Samba Member
Joined: October 01, 2017
Posts: 580
Location: Kent, England
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| Posted: Wed Aug 13, 2025 10:08 pm Post subject: Re: Engine build parts list? |
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Hi @Coastalbug
A couple of months back I just built my first engine. I had found a pretty decent DP 1600 AE Case, and for some reason, I too didn't really want to open up the case, so went for the 1800cc build.
Looking at the list, I think Glenn has pretty much got you covered, but will share the parts list I used to build mine ? In retrospect as Glenn also said, the CB builders choice kits look pretty awesome, but a lot of hassle for me here in the UK.
PS, mine was for use with a Bus, so emphasis was on mid range torque.
Trust me, you will get a lot of help on here. I could not have built my engine without the support from the Samba
Good luck
1800cc Engine Recipe/Parts List
AE Code AS41 case (Align Bored 1st over).
Engle W100 Camshaft
98g Engle Lifters.
Mahle Double Thrust Camshaft Bearings
AA 88mm thick-wall Barrels and Pistons
CB Performance (5.325”) H beam Con Rods
Kolbenschmidt Con Rod Bearing set
CB Performance Super Duty Pushrods, Aluminium cut to Length
AA500 (043) Bare Twin Port 1600cc (35.5mm x 32mm) Cylinder Heads (opened to 90.5mm)
New Engle HD single springs and Chromoly retainers
New Manley 32mm Exhaust SS valves
New SS valves 35.5mm inlet
CB Performance Super Stock Rockers 1.1:1
Thorsten Peiper Swivel Feet Adjusters
Weber 36IDF Dual Carbs
CSP Velocity Stacks for Weber IDF36’s
CB Performance Weber Filter and Hex Linkage Kit
Carter low pressure Fuel Pump 12v P90091
All OG Doghouse Tin with new Thermostat, from Awesome Powder Coat
Stock Cylinder cooling tins
New 70A Alternator
CSP Split screen Bus single quiet pack Exhaust (Heat and Dual Carbs)
Empi 4140 74mm Forged CW Crankshaft
Full flow in/Out Oil Pump and filter kit from CSP (Germany)
New Doghouse Oil Cooler and seals
CB Performance Breather Tower
Elring Gasket Set
CSP Cam Gear set
Cajero Accelerator Roller Tube CSP
CSP Stock 175mm and Billet Aluminium Pulley kit
New 8-dowelled flywheel
Andrig Evolution 1 Fan
Andrig Velocity Ring for Stock Doghouse Fan Shroud
Stock Bus 1200lb Pressure Plate
Bus 200mm clutch
CB Stainless Steel Windage Pushrod Tubes
Ross Wulf Viton Push Rod Seal set
New CSP Camshaft Plug
New Silverline Main Bearings (111 198 471T)
CB Fuel Block off plate with mount for Magna Spark coil
CB Magnaspark II Distributor including Coil, Leads etc.
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1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi |
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Dusty1
Samba Member
Joined: April 16, 2004
Posts: 2181
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| Posted: Thu Aug 14, 2025 8:01 am Post subject: Re: Engine build parts list? |
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| CoastalBug wrote: |
| Glenn wrote: |
| have your case cut |
That's what I'm trying to avoid if possible. Multiple machinists have said that for every 5 cases they get in, only one is suitable for rebuild. I'd rather keep this one running until it completely dies. |
You're from Texas so you should know bullshit when you see it.
Volkswagen rebuilders are gettin' a little thin on the ground. Even at that, there are shops who rebuild V8s all day and all night who don't have the tools or the skills to handle Volkswagen rebuilds.
Conversely.
Many "Volkswagen rebuilders" aren't machinists. The old douchebag near me doesn't even have a drill press. He's not set up to do case savers. He can't sleeve lifter bores. He has a worn out Porta Tool he'll shove through your case. He calls any case with thrust problems "beyond rebuilding".
If your guy doesn't have a surface plate and a Gerstner chest loaded with dial indicators, micrometers and bore gauges he might as well throw his metric wrenches away.
Hand a "machinist" a 1" micrometer. If he holds it properly you might have a chance.
So yeah. You're right. "If it ain't broke, don't fix it."
I have a T- shirt that reads,
Why be part of the problem when you can be the whole problem?
("You're either part of the problem or part of the solution.")
So:
Tools for rebuilding VW engines started arriving on the UPS and the FedEx trucks. Good luck finding a line bore tool although if you're real nice I'll leave you mine when I drop dead. Another Berg flycutter with a bunch of old timer extras showed up last night. My assortment of tools is expanding in every direction. Every tool acquisition suggests another tool that might be useful, for example I always thought a high end tig welder was out of my reach.
I have enough invested in tools I might as well have bought a CB Builder's Choice engine kit and been done with it. But... now I'm capable of the alchemy required to transform floor sweepings into a Builder's Choice engine kit so to speak.
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AlteWagen
Troll
Joined: February 23, 2007
Posts: 8702
Location: PNW
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MTT3107
Samba Member
Joined: September 20, 2021
Posts: 433
Location: KY
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| Posted: Mon Aug 18, 2025 9:43 am Post subject: Re: Engine build parts list? |
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Glenn posted :
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| Or buy a already built longblock for $4000. |
But that takes all the fun out of it….! |
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EVfun
Samba Member
Joined: April 01, 2012
Posts: 6222
Location: Seattle
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| Posted: Mon Aug 18, 2025 5:32 pm Post subject: Re: Engine build parts list? |
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| CoastalBug wrote: |
| Glenn wrote: |
| have your case cut |
That's what I'm trying to avoid if possible. Multiple machinists have said that for every 5 cases they get in, only one is suitable for rebuild. I'd rather keep this one running until it completely dies. |
How many miles are on this 1600 engine you are currently running? Do you know its real history or was it in a running VW you purchased? What is the crank end play? Have you checked lift to make sure the cam is not going flat?
If this is some low mile engine with in-spec end play and a good cam, known to be recently rebuilt and regularly serviced, you should be able to do the upgrade without any case machining except the cutting for larger pistons and cylinders and perhaps case savers.
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| Wildthings wrote: |
| As a general rule, cheap parts are the most expensive parts you can buy. |
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Tue Aug 19, 2025 10:06 pm Post subject: Re: Engine build parts list? |
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| MTT3107 wrote: |
But that takes all the fun out of it….! |
And learning experience!
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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CoastalBug
Samba Member
Joined: June 15, 2025
Posts: 116
Location: TX Gulf Coast
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| Posted: Tue Aug 19, 2025 10:10 pm Post subject: Re: Engine build parts list? |
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| EVfun wrote: |
How many miles are on this 1600 engine you are currently running? Do you know its real history or was it in a running VW you purchased? |
Well, I drove it to work today, and yesterday, and the day before. And I've had it at 70 on the freeway already. I also know that since I replaced the valve cover gaskets I haven't had to put oil in it in two weeks and it's no longer leaking oil anywhere.
But, it's a moot point for now. I got ahead of myself. Someone in my local club gave me some wise advice and said "I know you're excited but you have to make it stop before you can make it go." So now she's getting disc brake conversions and some other safety things. I'm going to revisit the engine build in a few months. I've got a spreadsheet that I'm building with parts and prices and links to videos and threads for information for now.
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Chris - 1968 Beetle Sedan, a book, and a lot of determination. |
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