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40hp big bore
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simon varley
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Joined: March 12, 2020
Posts: 175
Location: Geelong Australia
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PostPosted: Tue Aug 31, 2021 3:30 am    Post subject: 40hp big bore Reply with quote

I've not really visited this forum before. I posted my engine questions in the basic engine forum as I never considered what I had might be 'vintage speed' Very Happy

https://www.thesamba.com/vw/forum/viewtopic.php?t=757335

anyway, seems she is a 1962 remanufactured 1200 with a big bore kit. The car is a 1963 Ghia in Australia and the engine is clearly not the original, but seems that in the past someone has done a bit of work. This is what she has

    113 101 101 B single relief case
    6mm oil pump studs
    separate generator housing
    113 101 374 square rocker pedestal head
    30mm intake ?
    33mm exhaust ?
    83mm piston
    20mm wrist pin
    64mm stroke ----- 1385cc ??
    con rod 112 105 411A with a 'bump'
    109 tooth non o-ring flywheel
    28 PICT carby


so bits of it are from the original 6v, and bits have been upgraded. The bottom end looks to have been balanced

this is how it came out

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and these as it was stripped and cleaned. Not quite at the point of going back together just yet but it's close.



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next jobs - get the crank stripped, checked, measured and balanced. Order in new bearings when I know for sure the size.

Casing looks good but the camshaft still runs direct in the castings. Need to decide if it is worth getting it machined for replaceable inserts. The case looks good, but I've not actually measured clearances yet.

any suggestions greatly appreciated. thanks.
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FarmerBill
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Joined: July 25, 2017
Posts: 762
Location: New England
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PostPosted: Thu Sep 02, 2021 8:07 am    Post subject: Re: 40hp big bore Reply with quote

At the very least, I would get a bigger carb so you can take advantage of the extra displacement. If the cam/case clearance is borderline get the work done for replaceable bearings. It looks like you have case savers on some cylinders but not others? Hard to tell from pictures. I would make sure there are case savers all around. Other than that it's all about how much you want to spend.
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Rome
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Joined: June 02, 2004
Posts: 9603
Location: Pearl River, NY
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PostPosted: Thu Sep 02, 2021 4:51 pm    Post subject: Re: 40hp big bore Reply with quote

Your engine case cleaned up very well. What technique did you use? Machine shop hot parts washer?

Quote:
113 101 374 square rocker pedestal head
30mm intake ?
33mm exhaust ?

The book "How to rebuild your VW aircooled engine" by Tom Wilson has a full-page reference table of cylinder heads for VW type 1 thru 4. The 40 hp 1200 cc engine with the square/rectangular rocker pedestal is listed as 113 101 373, with 31.5 mm intake and 30 mm exhaust. I don't know if VW made a 374 head for other markets. Our resident 40 hp head specialist Glutamodo might know. Looking at your head photo closely, the last digit looks more like a "3" than a "4". The intake valves would have the larger diameters, and are the two fed by the center intake port in each head; in case you mistakenly "flipped" the dimensions around.

Your header looks like one purposely made for either a Ghia or a Type 2, with the lower pipes coming up close to the bottom of the upper pipes. This design makes for a compact layout so that the bottom pipes don't hang down as much as generic "Type 1 headers". The bottom pipes are thereby somewhat more hidden behind the Ghia's rear apron for a cleaner view from behind. So I suggest having them sandblasted, then ceramic coated or aluminized for longevity.
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simon varley
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Joined: March 12, 2020
Posts: 175
Location: Geelong Australia
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PostPosted: Fri Sep 03, 2021 1:43 am    Post subject: Re: 40hp big bore Reply with quote

Rome wrote:
Your engine case cleaned up very well. What technique did you use? Machine shop hot parts washer?


garage power wash with engine cleaner thouroughly rinsed off, and then elbow grease with scotchbrite red. only really took a day and had to be careful not to use the scotchbrite on any sealing faces, but in all honestly the case wasn't too bad. unlike the transmission.

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henry roberts
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Joined: February 24, 2003
Posts: 1274
Location: australia
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PostPosted: Fri Sep 03, 2021 4:45 am    Post subject: Re: 40hp big bore Reply with quote

those look like Sonic extractors, (made in Sydney, originally released in the 60's) with a different muffler. the original was a tiny hotdog muffler so yours is probably much easier to live with.

if you look closely you should see "sonic" in raised letters on the 4-2 merges.

looks like a fun motor.
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