40 horse big bore in 1600 case

[vwsteve]

I was putting a 40 horse together today with an old 83mm big bore kit and noticed one of the cylinders was cracked. I am thinking of using a 1600 case with 1500 jugs and using the 64mm crank and rods and the big bore 83 pistons. Has anyone ever done this? I will have to machine down the head side of the jugs to fit in the 40 horse heads and also shorten the jugs. This way it will be a stronger dual relief case with cam bearings and other than the case itself, no one could tell it wasn't a stock 40 horser. What do you think of the jug machining?

[glutamodo]

I've had idle thoughts of the same sort of thing you are propsing to do. My thought is, if you do the machining right I don't see why it couldn't work. I take it you have some 1500 jugs around, because they are not exactly commonplace items.
-Andy

[vwsteve]

Before I go this route, does anybody out there have a single 83mm big bore jug for a 1200 case that they would like to sell or trade? If not, I think I will look for a set of 77mm P&C's to complete this motor for now.

[glutamodo]

I seen one in the Classifieds a while back... let me look.

Yep still there. It's an old German one though so it's hard to know for sure if it may or may not match the dimensions of your other ones. Here's the link:

http://www.thesamba.com/vw/classifieds/detail.php?id=695581

Also, I know I have a couple of spare used ones, I think mine are probably Cofap or Mahle.

-Andy

[vwsteve]

Thanks. I searched for an hour and didn't see that. Mine are Cima. The crack was at the top and I went ahead and broke the piece out. About one inch triangle not going down past top ring. I actually ground the edges and clamped it back together then heated the area to a dull glow and mig welded it back. Believe it or not, after welding on inside and outside and very careful grinding, it looks pretty good. I don't think I warped it either because the piston fits good.