1776 Ready for a complete rebuild

[Murt]

Hi Gentleman
Well after the so far very successful 1800cc Build, and ready to build a 2007cc
I have a small change in plans.
I decided today to put the 2007 on the back burner for a while, and really want to get my Bug back on the road. The poor little thing has sat under cover for the best part of 2 and a half years
It is the very reason I decided to build an engine in the first place, as I had paid a lot of money to have this built for me, and only got about 200 miles on it before a knocking sound started around that time I had the Bus anyway, and the poor old Bug sorta just got forgotten.
Anyway. Back story is that I have no build sheet, only what the builder told me in 2019. Covid then hit and when we eventually tried to install the engine, the Builder had passed over
This is what I'm working with Built Dec 1965, so a UK supplied 66MY.
New VW AS 41 case
Bergman 69mm c/w VW crank kit
VW 311 rods
Engle 110 cam kit
Barrel/Piston kit 90.5/1776cc MAHLE
Mofoco 042 heads 40x35.5
Full flowed Schadek 26mm oil pump kit
Dual Dellorto 40 mm carbs with CB manifolds and Vintage speed linkage
Vintage speed big exhaust
Bergmann Porsche fan kit
No Heat
As I said, I uncovered her today, and have removed rear brake and fog lights, and have removed the bumper. I will post some photos of her today, but Ideally looking for advice on a complete rebuild ?
I'm a lot more confident about engines than I was then, and very pleased that I'm at the point where I think I can pull this engine and re-build it myself.
PS: in my stash, I have a new CBP 74mm Crank, and a new set of stroker clearanced 5.4" rods. I'm hoping to re-use the (90.5mm) B&P's, and the Mofoco heads. but not sure whether the W110 is the right choice ? I never wanted a 'screamer' but somthing that will cruise at 60mph, room to accelerate and pass lorries, 5500 rev limit ? Still has the OG Gearbox which was clearanced for 200mm flywheel. I would really like to have this old girl ready to run for next year.
As always, your thoughts are more than welcome

_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Brian_e]

Does it still turn, and it just knocks, or is it locked up?

I would tear it apart and see if the crank survived. If not, use the 74mm. Figure out what the knock actually is.

It might be a bad cam gear sounding like a knock.

The cam and heads aren’t ideal, but they will work with a little touch up on the heads. They are also paid for at this point

I think you are plenty capable to knock this one out now. Tear it down, investigate as you go, find the problem, then start from scratch with all these parts on the bench. Build it just like you did the 1800cc. Don’t skip any steps, measure everything.
Brian
_________________
So more or less the lazier and stupider you want to be, the nicer quality parts you need to buy.
-Modok

Narrowed beams, Drop adjustable spring plates, Bus disk brake and IRS kits.
www.type-emotorsports.com

Type E Engine Parts and Supplies
https://type-emotorsports.com/collections/engine-parts

[Murt]

Thanks Brian
No, engine turns over fine, I have no idea where the knocking is coming from, and as you say, will have to strip it right down and and check everything, was hoping to keep the $$$$ spend to a minimum on this one, and as I said, has approx 230 miles on the clock from new, so praying not too much damage, if any ?

Good news is that I have a removable rear apron, so once I get her in the air I can get the rear wheels off, and remove the fenders and the apron, and get the engine straight on the stand.

One of the things I will be asking along the way is about cooling though, as not too clued up on the Bergmann shrouds. Hindsight is a wonderful thing, and in retrospect I wish I had gone for a straightforward Type 1 shroud with all the correct OG tins, but back then I was blinded by the bling and did not understand the science. I could of course still go back to type 1, but still like the 'look' I just want to do right for the engine/car if that makes sense ?

I will be spending on a new Thermostatically controlled Filter head, something like the Improved Racing one I have on the Bus, or a Mocal unit, and will be also looking at the Empi cooler and fan on there, as on the Bus I have the Setrab/Spal kit, and they seem to be quality.

I'm hoping the Crank is OK but as you say, I have a new CB 74 to fall back on. If it's the cam gear, I have a new one, along with a new W100 cam and new Engle 6001P lifters, but would probably want a suggestion of something more suitable for the Bug ?
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Zed999]

Did you have those vents put in the engine lid? My 65 didn't have those though it was still a 1200.

[Murt]

Forgot to add
The Cam break-in was done by the builder, and oil was changed. The engine was finally fitted in July 2021, and was started in the car. I did about 220/230 miles, and drove it quite hard, and then the knocking appeared I have not really driven it since, and have not changed the oil since then either

https://youtu.be/Xe2NHMkf_h4
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Murt]

Hi @Zed999
No, The decklid I bought, it was from a 64 Vert I believe. I bought this and also stand offs as even from day one I had trouble with it spitting and farting ? and wondered if it needed more air ? Don't think those dells were ever set up fully correct ?
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Clatter]

“Knocking” can be a lot of things.

Are you -sure- it’s an internal noise?

Mayne try starting it up without the fan belt on, see if it’s related to the fan?

Also,
Is it 1/2 crank speed?
Some valvetrain failures can be fixed with the engine in place.

Hope springs eternal.
Sucks to pull an engine apart and find nothing amiss.
BTDT.
_________________
Bus Motor Build

I have excellent news for the world...
There is no such thing as patina.
It does not exist!

[Murt]

Hi @Clatter
That's strange you said that, as about a year or so ago a friend of mine said are you sure it's internal ? To me it definitely sounds internal, but I'll be back there at the workshop tomorrow, and for giggles will probably try and start it without the belt, although I may have problems getting it to run as it's been standing for quite a while.
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Zed999]

[Murt]

Cover is off. And pulled her out of the grain store today, Engine is coming out tomorrow with luck.
Actually really looking forward to getting her back on the road, and I think she's a pretty little Bug.

The big decision is whether to go back to stock tin-ware, Doghouse cooler etc, or stick with the Bergmann

Oh well, we'll see what the 'knocking' problem is first

_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Murt]

Had a good day today and the engine is out. Prior to the start of the knock starting, I had a horrible squeal from the clutch as well.
This is what it looked like as we pulled the engine. The Throw out bearing moves all over the place ? Something is not right

_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[early]

Ring on pressure plate is missing.

That would make some noise.


I did that once 45 years ago. Ha!

My 68 bus made it to alberquerqe, NM. Before clutch to bearing kicked sideways and came loose.

Drove all the way to Santa Maria, CA with no clutch. Trashed synchro in that box.
What a story that was! And I was flat towing a 63 vert to sell at orange county swap meet.

Wonder what became of that vert? It was nice.

Fix the pressure plate.

[67rustavenger]

[Murt]

Hi @early
Sounds like that was a fun trip
So, I tried turning the engine over with the belt disconnected, Fan spun perfectly, but the noise was still there.
The throw out bearing was barely on, and there was a lot of movement on the shaft in all directions, so new throw out bearing and clips ordered, and a new PP.
I can't see how but would that possible be the 'Knocking' sound ??
Dropped the oil, and no word of a lie it was crystal clear and golden, could not find any contaminants, plus the filter was the same, although I didn't cut it open.
Anyway, going on the stand tomorrow, and will fit the Zalex starter ring, and spin it over again to isolate the clutch ?
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Murt]

67rustavenger I was typing as you posted
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[sled]

[oprn]

My mismatched set actually lasted 2 summers and about 15K km before it scattered! And scatter it did! I was picking balls out of every possible nook and cranny inside that bellhousing! Some were even jammed deep in between the pressure plate diaphragm and it's housing.
_________________
Our cars get old, we get old but driving an old VW never gets old!

[Murt]

Hi @sled
Unfortunately, I never built the engine, or fitted it
Back then I was a complete, and I mean a COMPLTE newbie. This engine was what forced me to learn all I could about Aircooled engines, as we had put over $10k dollars into having an engine in our bug, only to go 230 miles
When I retired at Christmas, I already had a plan in place to learn my trade on the 1800cc build, and feel I am in a much better place. I have had some absolutely fantastic support from the Samba, and without sounding like a cock, I could not have learned what I know now without you guys that have took the time to help me.
I'm really looking forward now to getting this engine squared away.
Dave
_________________
1966 VW Beetle ‘Jules’
1967 Kombi Splitscreen ‘Barney’
2018 VW Caddy Maxi R Line
2017 Golf GTD saloon
2008 VW EOS 2.0 TFSi

[Zed999]

[67rustavenger]