Stock 1600 DP rebuild, step by step

[eschmi]

that's why I was asking to be 100% sure, I've had people tell me to paint the inside too but I thought it'd end up getting the oil as you said, that's why I asked even though it's kind of a stupid question. I'd rather consult multiple sources to make the right decision than mess it up and screw up an engine.

[Keithinky]

Maboyce,

Awesome. Thanks for putting this on the samba for all of us. Looking at how thorough you were I can see it was very time consuming- engine work and writing, pic posting.

Thank you. Keith

[TheDon]

I am so glad the thread author used the photo hosting on TS for all of his detailed photos. I just ordered the same book and have a single port engine to rebuild. This thread is great
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[dagen_1]

still a valuable thread in 2018. thanks for the detailed posts and pictures.

many thanks!
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74 Super Beetle

[firengine103]

Great thread, Thank you!! Jim E. OKC

[loctiteis]

[quote="maboyce"]Exhaust system and tinware

Last year at this point I noticed a broken-off tin screw on one of the cylinder heads. I had to use the mig-welded nut trick to remove it, and then clean up the hole with a tap.

I recommend filing bolt top,placing good fitting washer over, welding connection,then tacking nut or bolt to washer, letting cool, then penetrating oil and work back and forth a bit before removing entirely. then use broken bolt with small zip cut slot through thread length as chaser,saves time on chasing the rest.
Great post,following with interest and concentration.

[Zundfolge1432]

Here’s what I did using only a die grinder and a drill.

https://www.thesamba.com/vw/forum/viewtopic.php?t=666653&highlight=