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Grapes of Wrath $200 engine rebuild
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Bill271
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PostPosted: Thu May 24, 2012 6:13 pm    Post subject: Reply with quote

VERY GOOD! but as a side note i would check the # 3 rod bearing closely, there was a lot of wear on the skirt compared to #4 also the case (well it was hard to tell) looked fretted on the rear main. i would rec sticky also.
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johnnypan
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PostPosted: Fri May 25, 2012 6:25 am    Post subject: Reply with quote

Excellent work..I build engines along the same lines.

Ive found that close inspection and reuse of mahle pistons and cylinders saves money too..the leading inspection indicators for me is scuffing above the top ring,wrist pin fit and cylinder ridges...often we deal with a second or third rebuild on an engine and the slugs and jugs are still servicable.

I wont use a used head thats been rebuilt..if its flycut and used most times its done,but if it has the cylinder ridge and good valve protrusion wit no obvious cracks it is a good candidate in most cases..last pair of DP's I picked up for 50 a piece were excellent original heads,with minimal wear..
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auslander
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PostPosted: Fri May 25, 2012 6:55 am    Post subject: Reply with quote

EPIC!!! Very nice write up, im sure this will help alot of people
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AlteWagen
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PostPosted: Thu Jun 07, 2012 10:27 am    Post subject: Reply with quote

I thought I would ad that the July 2012 issue of HVWs mag had some more good tips on inspecting a used case.
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AlteWagen
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PostPosted: Fri Jun 08, 2012 12:22 pm    Post subject: Reply with quote

Just saw your $40 engine build JP. Had to add it to this thread to show what can be done on the cheap.

http://www.thesamba.com/vw/forum/viewtopic.php?t=505196
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Muthashabubu Premium Member
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PostPosted: Wed Oct 03, 2012 11:35 pm    Post subject: Reply with quote

Any word on when part2 might be done? I just read this thread and it's exactly what I needed to boost my confidence! Great down to earth stuff.
Bought a non-running bus and i'm hoping to get it moving by the end of the year. Never built an engine before but i'm good with my hands.
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AlteWagen
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PostPosted: Thu Oct 04, 2012 12:04 pm    Post subject: Reply with quote

I started a new job so time has been tight.

Like mentioned before by me and others, used heads are a REAL gamble. Being that new p&c are cheap and the new chinese heads are also inexpensive I would recommend using them. The last thing you would want is to shred your pocket book and confidence due to a dropped seat or broken valve!

I still will finish part two on head and piston/cylinder inspection in the next few months as time allows.
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17 mm
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PostPosted: Fri Jan 18, 2013 11:45 pm    Post subject: Reply with quote

Nice thread! I am a lurking motor builder myself Wink Actually this is my first post! Good work!
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CoastalAirCooledVW
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PostPosted: Thu Oct 10, 2013 8:29 am    Post subject: Reply with quote

How is this engine doing?
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AlteWagen
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PostPosted: Thu Oct 10, 2013 11:05 am    Post subject: Reply with quote

Ive put another 34K miles on it since the "rebuild" and its still going strong in the bus. These have not been easy miles! Its first big trip was from Albuquerque back to L.A. in the middle of the summer with only 100 miles and one oil change under its belt, crossing the Mojave mid day at 108* was interesting. Several loaded trips back and fourth to Sacramento, regular use as a shop vehicle hauling loads to Pomona swap meet and daily driver status for most of the year. Not as many off road miles as Id like but still gets dirty on a regular basis.


Link


Still getting 25-28 mpg with out the roof rack and a blast to drive. I would not hesitate to get in the bus and drive cross country without a worry.

With the cost of a new case at $1K I think this type of build will become more popular.

I have been collecting some used heads to finish up part II, I should have it done shortly.
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Anthonyisawsome
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PostPosted: Thu Oct 10, 2013 2:22 pm    Post subject: Reply with quote

This is how I built my first engine. New pistons and liners, bearings, gasket kit and everything else needed to get it running like spark plugs, carb kit and other things. Cost me just under $400. I was given a whole bunch of stuff from my dad and he helped me build my fist engine. I just have a feeling it will not last long the way I drive it Laughing
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johnwesley
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PostPosted: Sun Dec 01, 2013 7:05 pm    Post subject: Reply with quote

so do we have part two ???? Smile
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PostPosted: Tue Dec 24, 2013 3:44 pm    Post subject: Reply with quote

I love this post, I have a few budget rebuilds under my belt and to my knowledge all of them are still running. The last two bone stock engines I opened up both had broke cam gears! Shocked To be safe I always use a cam with a bolt on gear. And most of the time I'll put in a new cam and lifters anyway.
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UncleWeno
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PostPosted: Tue Mar 11, 2014 3:41 pm    Post subject: Reply with quote

Shocked Very Happy this is just awesome! just the perfect write-up for me. i'm researching right now to finally tear down/rebuild my 1600DP out my 68' squareback.
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PostPosted: Tue Jun 03, 2014 6:43 pm    Post subject: Bookmark Reply with quote

Maybe I can't find it, but I wish I could subscribe to this thread. This is what I've been looking for and didn't know it.
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SBD
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PostPosted: Tue Jun 03, 2014 9:28 pm    Post subject: Re: Bookmark Reply with quote

GasOilnSteel wrote:
Maybe I can't find it, but I wish I could subscribe to this thread. This is what I've been looking for and didn't know it.
When you post to a thread there is a box you can check that says "Notify me when a reply is posted." Otherwise, at the bottom left of the thread is a spot you can click that says "Watch this thread for replies" or something like that. Just click it and you should get an email whenever there's a post to the thread. Cool
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sb001
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PostPosted: Mon Jul 14, 2014 7:23 pm    Post subject: Reply with quote

I'll throw my hat in the ring too- fantastic post, a wealth of detailed info (and great pics) for those of us just getting started on this. The time will soon be here where I am going to try to tackle a rebuild on my broken engine, and I have a feeling this thread will prove invaluable-- as others have stated it gives me the courage to jump in with both feet. Please post part 2 asap! Smile
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AlteWagen
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PostPosted: Tue Jul 15, 2014 1:21 am    Post subject: Reply with quote

sorry to not have part 2 up yet but been too busy livin life these days. It seems that dealing with crap parts and shady vendors in the VW scene has taken the fun out of it for me.

Ive been spending more time traveling and camping so garage time has been limited to routine service on the aircooled part of the fleet. Most of my time has been spent on my 1972 K20 suburban and my 1965 C10 Carryall, much easier finding NOS parts at reasonable prices.

My recommendation is still to save up and get new heads as the most reliable option as 40-50 year old cores are a real roll of the dice.
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Teafortwo
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PostPosted: Fri Aug 07, 2015 12:24 pm    Post subject: Reply with quote

Hi. Great thread.

Just a final question. How do you deal with the different sizes in Cam Shaft gear? VW had a variety of stock sizes to cope with variations in production. Unfortunately no one supplies different size Gears and few of us have a box of used ones under the bench.

Help. Please........................
I want to do this right.
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GTV
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PostPosted: Fri Aug 07, 2015 1:09 pm    Post subject: Reply with quote

The new gears are one size fits all. The right way to do it is get a few stock original gears (-2 to +2 does the majority of engines) and trial and error until they fit right.
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