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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Fri Dec 30, 2016 1:51 pm Post subject: Re: another 40HP 1385 build |
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Have decided on a FK41 cam and 1.25 rockers, Engle lifters, single HD springs...
hopefully the crank is in good shape and I wont need to rebuild that as well. Still keeping it under the $600. Haven't factored in any machine shop costs...hopefully none is needed and if so hopefully they wont break the bank.
Thoughts?
I'll continue to update this post with pics and current status. |
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Bulli Klinik Samba Member
Joined: January 16, 2005 Posts: 2067 Location: Bulli Klinik, Colorado Springs
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Posted: Sun Jan 01, 2017 11:25 am Post subject: Re: another 40HP 1385 build |
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I've used both the 100 and C25. I really like the Engle 100 and it runs well with a stock carb.
I'd crank up the compression to 8.5:1 or so. I built a similar combo for a local Baja and it was crackin' little motor. _________________ I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs |
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Matthew Samba Member
Joined: January 29, 2004 Posts: 1760 Location: Eastern Tennessee
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Posted: Mon Jan 09, 2017 4:45 pm Post subject: Re: another 40HP 1385 build |
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You need to stay really mild with the cam timing with such small heads and intake. I think the CB2280 "cheater cam" would be best. The Engle W100 would be max for that engine combo. _________________ 1965 Beetle sedan
Click to view image |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Tue Jan 10, 2017 4:41 pm Post subject: Re: another 40HP 1385 build |
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All parts just arrived. WOOHOO. Going to get my garage cleaned up and ready for the job! |
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bug_65 Samba Member
Joined: October 01, 2011 Posts: 14
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Posted: Thu Jan 19, 2017 4:23 am Post subject: Re: another 40HP 1385 build |
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with the extra lift of the cam be careful that your spring retainers dont bottom out on the valve boss. I had this problem which caused some grieve.
I m current running 1385 with engle 100 and 1.25.1 solid rockers, but only standard 1600 springs and appears to be ok for the past 4 years.
By the way dont listen to the bone heads saying put a 1600dp in. blah blah.
Something to be said that the little 40hp 1385 is more interesting. |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Tue May 09, 2017 12:23 pm Post subject: Re: another 40HP 1385 build |
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as with most projects, life got in the way....work, kids sports, etc. However some quick updates. All parts for this are in - which is good so I am not really waiting for anything. I have cleaned up and set up a dedicated space in my garage...so really its finding available time. I am finishing up a rear brake job / transmission flush and since the weather is starting to get really nice I may drive it as is for a while. Goal is to finish the engine before I go to OBX this August. Wanted to tow the Buggy down there and have some fun at the beach. I'll be sure to continue to update this thread in three parts, 1) tear down and inspection, 2) Clean up, rebuild 3) test and tune |
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calebmelvin Samba Member
Joined: July 19, 2006 Posts: 3140 Location: Seattle, WA
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tisius Samba Member
Joined: July 11, 2011 Posts: 1570 Location: Rotterdam,NL (+Chicago,IL)
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Posted: Thu Sep 06, 2018 3:37 am Post subject: Re: another 40HP 1385 build |
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prkid424 wrote: |
So eventually there is a 1600dp but I got to learn with what I got. I do have a budget of $600 to get this engine refreshed. $600 won't get me a running 1600dp. I absolutely enjoy the challenges and it's my passion to tinker with everything. The 40hp build is just to wet my appetite and get more pep. |
I like how you're thinking!
Yeah, did you finish your engine build? _________________ drive it like you just robbed the bank
you don't have to be crazy to be into VW's, but it sure helps!!
.... if it ain't dutch, it ain't much! |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Fri Feb 15, 2019 1:03 pm Post subject: Re: another 40HP 1385 build |
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Life always gets in the way......engine is still as it was. Loved driving the buggy almost daily all last summer though- smiling every single time!! Finishing up a few honey-dos then its 100% engine work. I will absolutely post up here as it goes.
Question- re-looking at all parts I have purchased and more research that I have done.....with the 1.25 rockers and the FK CAM I will most likely need to “cut to fit” push rods right? |
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thomas. Samba Member
Joined: July 31, 2010 Posts: 1288 Location: South West (Pa.)
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Posted: Fri Feb 22, 2019 4:24 am Post subject: Re: another 40HP 1385 build |
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If it was me I would pull the engine and install the big bore P&C . For all the hassle of splitting the case and breaking in a new cam & lifters how much more power difference could it make? On the other hand the 1385 with a bump in compression will make a notable difference. Plus, it can be finished in a weekend of free time. You can always sell the n.o.s. parts or use later. |
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fl59bug Samba Member
Joined: November 23, 2005 Posts: 1976 Location: North Carolina
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Posted: Fri Feb 22, 2019 7:40 am Post subject: Re: another 40HP 1385 build |
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thomas. wrote: |
If it was me I would pull the engine and install the big bore P&C . For all the hassle of splitting the case and breaking in a new cam & lifters how much more power difference could it make? On the other hand the 1385 with a bump in compression will make a notable difference. Plus, it can be finished in a weekend of free time. You can always sell the n.o.s. parts or use later. |
Which big bore kit do you mean? I might have not caught it but didn't the O/P go with the 83mm big bore kit already to achieve 1385 (up from the original 77mm x 64mm 1192cc)? |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Wed Jan 22, 2020 9:40 am Post subject: Re: another 40HP 1385 build |
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Looking back at this post I can’t believe that much time has passed since I first started contemplating this rebuild. The good news is that I drove the hell out the engine this entire time- almost daily when the weather was nice. But now....it’s most definitely time. Last couple weeks I pulled the motor and started disassembly. I work an hour so every evening. Taking my time- not rushing it so this won’t be a quick “weekend build”. Hopefully tonight or tomorrow I’ll split the case. Then this weekend the block, crank, heads will go to machine shop for line bore, polish, balance, flycut etc. Pics are worth 1000 words so....
Motor Pull:
Fan Shroud, Tins, and accessories off
Heads off:
Jugs off:
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Tue Feb 11, 2020 9:27 am Post subject: Re: another 40HP 1385 build |
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Finally have all my parts back from the machine shop.....work done:
*Full Balance of complete rotational assembly
-crank, flywheel, pressure plate, pulley
*Piston and pins balance
*Rods balanced
*Align bore checked
*Head Work
-grind seats
-refresh guides
-valves
-balanced spring pressure at both static and compressed state
-fly cut
-porting
*Wash all parts
I am super excited to get started. Next up is setting up the garage as a "clean engine building room" to start the mock ups, blue printing, and final assembly. May need to take cylinders back to get turned down for the proper compression that I am going for.
BEFORE:
AFTER:
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Danwvw Samba Member
Joined: July 31, 2012 Posts: 8892 Location: Oregon Coast
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Posted: Tue Feb 11, 2020 11:57 am Post subject: Re: another 40HP 1385 build |
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With an FK-41 cam on a 40 horse I would just run 1.1 Stock VW 1600 rockers and solid rocker shaft's with elephant feet adjusters from CB or maybe Scat Ball adjusters with those single hd springs, light weight lifters, Stock Pushrods if you don't mess up the engine width much. If you do run 1.25 ratio rockers you will need racing aluminum pushrods because the stock pushrods will wear against the 1.25 rockers. I like the Stainless Steel wide mouth racing Pushrod tubes CB performance sells when running ratio rockers.
With the stock carb manifold and heads. It will idle rough but sound nice and if decked, cc-ed and balanced it will run amazing smooth at RPM. Cruze is still going to be 65mph but it will pull up to 75 or 80 with the big tires. Keep and eye on oil pressure. I would full flow the case and run a remote filter. Or perhaps a FilterPump Don't go over 26mm on the oil pump size on a single oil pressure relief case, also don't run a sump. Stick with 5W30 or maybe 10W30 VR-1 in hot weather. If you run regular motor oil ad a 1/2 bottle of ZDDP to each oil change. This will protect the cam and lifters against excessive wear. Be sure to follow the cam break-in procedures which involves 20 minute 2000 RPM or so run the first time you start the engine. _________________ 1960 Beetle And 1679cc DP W-100 & Dual Zeniths! |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Tue Feb 11, 2020 4:37 pm Post subject: Re: another 40HP 1385 build |
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Danwvw wrote: |
......It will idle rough but sound nice and if decked, cc-ed and balanced it will run amazing smooth at RPM.
....... Keep and eye on oil pressure. I would full flow the case and run a remote filter. Or perhaps a FilterPump Don't go over 26mm on the oil pump size on a single oil pressure relief case, also don't run a sump.
Stick with 5W30 or maybe 10W30 VR-1 in hot weather. If you run regular motor oil ad a 1/2 bottle of ZDDP to each oil change. This will protect the cam and lifters against excessive wear. Be sure to follow the cam break-in procedures which involves 20 minute 2000 RPM or so run the first time you start the engine. |
Why would it idle rough?
Who do you not recommend a sump?
VR1 is all I e ever used and I add a zinc additive |
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Danwvw Samba Member
Joined: July 31, 2012 Posts: 8892 Location: Oregon Coast
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Posted: Tue Feb 11, 2020 9:02 pm Post subject: Re: another 40HP 1385 build |
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You don't add Zinc to VR-1 it already has the right amount for a flat tappet engine.
If you run a sump on an engine like a 40 horse that has a small pick-up inlet tube to the oil pump you get intermittent loss of oil pressure. Too much restriction in the oil flow so they suck a vacuum, there can be cavitation in the oil pump especially if revved cold or hot with 20W50 oil or with big oil pumps.
As far as idle goes with a stock carburetor and manifold it doesn't take much cam to give it a cammed up sound.
Outside the 83mm bore and increasing the CR with stock 40 horse heads there isn't much you can do for them. The valves and ports are just too small. The valves are so small that lifting the intake valves much more than stock won't have much effect. 1.25 ratio rockers would lift the valve .455" or something which would be good in a 1600 but not used in the 40 horse. The stock cam only has .314" of lift but with the cam FK-41 your planing even 1.1 Ratio rockers will give over .400" of valve lift. If you increase the manifold size on a 40 horse the gas just condenses out on the inside of the manifold, If you increase the venturi size in the carb it may have more top end however it probably wouldn't idle.
I built a 1585cc single port once with a W-100 camshaft and ran a stock 40 horse carb and it was a good combination. Great MPG's good mid range torque. Your choice of the FK-41 cam is interesting it may work nicely. _________________ 1960 Beetle And 1679cc DP W-100 & Dual Zeniths! |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Thu Feb 13, 2020 8:10 pm Post subject: Re: another 40HP 1385 build |
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All laid out ready to get started. I’m sure I’ll probably mock build this a few times to get all the right measurements.....will continue to update as the build moves along.
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heimlich VWNOS.com
Joined: November 20, 2016 Posts: 6559 Location: Houston, Texas
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Posted: Thu Feb 20, 2020 11:15 am Post subject: Re: another 40HP 1385 build |
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That's a nice shop with the milling machine, etc. Is that all in your garage? _________________ www.vwnos.com [email protected]
Classic Brands. Classic Quality.
Not all parts are made the same. NOS OE/OEM parts made mainly in West Germany, Early Germany, and Early Brazil are where VW produced the best quality parts and best fitting products.
5% Off your order with coupon code: 5%OFF
Restored Distributors Available (<--Click here) |
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spencerfvee Samba Member
Joined: August 19, 2004 Posts: 3071
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Posted: Fri Feb 21, 2020 5:37 am Post subject: Re: another 40HP 1385 build |
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hi heres my two cents on your build .why a fk41 cam ?are you building a all out race motor. or a friendly street motor. I looked this cam up on the net . it is for serious motor builds with dual carbs or a big single carb . you must run dual springs the add says. its rpm rang is from 1,000 rpm to 5,000 rpm . are you going to run a stock 28 carb ? or a 30 carb ? if you are I feal the fk41 cam is a over kill for a 40 hp motor . I don't think your going to be happy with that cam for the street your going to be in 3rd gear a lot .for get 4th gear. my self I don't like 1:2.1 rockers there a pain in the ass to set up. unless you buy a set of scat $200.00 + that has the right off set .on a deep sump. I have used a deep sump on formula vee 40 hp motors . they work just fine using the small pick up tube. don't get me wrong. I like 40 hp motors and dune buggies . I just want you to think about what your doing on your motor build . and ask your self am I doing the right thing on my build . your the one that has to live with your motor. my goal was not to put you down on your build .please think over what your doing .ask engle if your using the right cam good luck like I said just my two cents spencerfvee |
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prkid424 Samba Member
Joined: April 21, 2015 Posts: 171 Location: Wodbridge, VA
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Posted: Fri Feb 21, 2020 10:18 am Post subject: Re: another 40HP 1385 build |
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heimlich wrote: |
That's a nice shop with the milling machine, etc. Is that all in your garage? |
I wish.... |
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