Engine advice (budget speed)

[Little Car]

I just purchased a 63 bug and the previous owner was in the middle of doing a 12V conversion so I'll finish that, but am looking for the best option when it comes to the engine. I am mechanically capable so I can do all but the machining work but this is my first actual "hands-on" experience with a classic bug.

The car has currently installed a 1500sp (case code H5) which I hear isn't worth the effort refreshing, and also the original 40hp (late 63) that came with it. I haven't torn into them yet however both engines turn over freely so that's promising.

My plan, at a minimum, is to buy the big bore kit from AA, a set of 1:1.1 rockers, maybe a different carb than the 28 PICT that I have, and rebuild the engine so everything is fresh. Hopefully this should give me enough pep and reliability for me and my boys to enjoy the car for the next few years until I get out of the military.

My question (finally) is should the need arise would it be possible or any benefit to slapping the internals from the 1500 in to the 40hp case? I ask because I know you can place the 69mm crank in it no problem, also there seems to be word that the 64mm crank is not that strong, and the big bore kit is the same bore as the 1500 already. So I don't see any reason they won't fit the case. Also shouldn't I get bigger valves with the 1500 heads?

Trying to keep this a low budget build for now and get it back on the road maybe by the summer.

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1500cc H block are good for little bore "cc " engine builds ..only folks that don't like the H block 1500cc cases are the ones that drag race and that are looking for the strongest case and the H block ain't that great for what they want so to them it's junk ...but if your planing on building a 1500cc there's nothing wrong with it for that/this type of build just add case head stud savers ... if your on a budget I would just fix the H1500cc engine if your planing on swapping 1500 parts to the 40hp case the case bore will need to be machine open for the 83mm bores/cylinders ..extra money spent also I would add case savers to the 40hp case As well ....so it's really up to you if you want the 63 engine block to match the same year as your car ....but if your that type who don't care about matching numbers than just go with the 1500cc and just build that ....and add dual carbs our a single zenith 32 ndix manifold/ carb there are plenty of these zenith single manifold in the classified ads here in thesamba ..... there are so many ways to go/ build its just gonna be up to your liking....

[Little Car]

Yeah not really a stickler for numbers matching. Down the road is when I plan on placing the hot rod motor in it. Right now just mainly looking for the most reliable option (providing the engines aren't FUBAR when I disassemble them), and if push comes to shove what are the interchangeability of parts between the two.

I'm glad you mentioned having to machine the bore holes for the 1500 pistons because it was my understanding that with the "big bore 40hp" kit the Pistons/cylinders just slipped right in. Shy of people saying the piston skirts would need to be machines shorter on the AA kit.

This is mainly supposed to be a fun project for my boys and me don't need a money pit. That's what my Z is for 🤣

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[Little Car]

Thanks! Lots of great info.

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[Iowa Mark]

Or use the H case and build it to look old. Like this.

[motofly196]

At this point, I'd bet your 1500 is a 1600 anyways. It was very common when those got rebuilt.
40hp big bore kit doesn't need any case machine work at all using the 64mm crank (original crank to the 40hp) and the 83mm Big Bore pistons. There is really no need to dump a ton of money into the weaker 40hp engine. 40hp engines don't use cam bearings, so check those cam journals 1st to make sure they are in good shape. I'd see what kind of shape your 1500 H case is in.
40hp big bore is 1385cc. I just built one last summer from parts I had acquired over the years. On the NOS NPR piston and cylinder kit I had, I needed to do minimal piston skirt clearancing on #3 piston. Then rebalance the pistons.
It isn't a ton of work to do, but in my opinion...you're money ahead building a 1600 out of your H-case for now. Cheaper to do to. And A LOT more power....

[Little Car]

That's nice, would be easier/cheaper to eventually go dual carb'd if I would want in the future than the 40hp. More to come as I begin to break down this 40hp this weekend.

I do like the idea of more displacement in the H5 providing it proves to be a good motor. Both motors were running and still turn fairly freely yet the last time either of them ran was when the car was stored back in 1995. So whichever one looks in the best condition is the one I'll rebuild. This is just to be a stand in motor for at least the next 5-10 years of summer/weekend fun not a powerhouse. Most I plan on either one is basic powermods (rockers, carb, port & polish, big bore for the 40hp)

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[Braukuche]

I’ll toss this out there, If the 40hp is the original engine to the car, then that’s pretty rare and worth saving. Numbers matching early VWs are rising in value. It would be the perfect candidate for a true vintage speed build down the line, with increased displacement, vintage dual carb set up, etc. that’s expensive but makes you car different from the vast majority of replacement big 1600 based cars out there.
I would agree with those who say rebuild the 1500 for now and pickle the 40hp until you are in a place to consider what makes most sense for you.
Good luck.
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[Little Car]

I don't know if it is the original motor that came in it in 1963, but the motor is a late 63 and I know the body/chassis are number matching 63.

It is tempting to try and build a dual carb, big bore 40hp with all the vintage speed parts but that is way out of my budget right now. Still I like the idea.

[Rome]

[Braukuche]

[Lingwendil]

^ that engine just screams that it needs a abarth type four-tip exhaust like the vintage speed and flat-four ones! Love the look of the stock aircleaners.
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73 super beetle thread http://www.thesamba.com/vw/forum/viewtopic.php?t=649622 Back on the Road!

Modify your Kadrons for SVDA http://www.thesamba.com/vw/forum/viewtopic.php?p=8115884#8115884

Cast iron VJU4BR8 SVDA reference thread- https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Need replacement filters for original Kadron aircleaners? WIX #42087 is a perfect fit, as is Napa Gold #2087!

[Little Car]

Well, finished tearing down the original 40hp from the bug and overall looks like a solid rebuild candidate to me so far. The bearings are tight in the case and don't show crazy wear to me.

However there seems to be some negative signs that would be fixed with a rebuild. The engine had .07" endplay on the crank and seemed to be missing the appropriate amount of shims on it. The #1 & #2 cylinder's upper compression rings were broken and seemed to have a little damage to the #1 piston. Cylinders look fine though.

#3 & #4 head shows signs of what looks like blowby around the mating surface between them, also added that the nuts were not as tight feeling on that side. Also don't know if this is normal piston gap in the #3 but seems excessive to me.

The biggest issue in the rocker arm stud around the #3 stripped out of the head which would explain why the rockers for that cylinder were loose. I've hear and seen vintage kits to tap and repair them but finding them will take a while. Is there a way to tap the head and put in the shorter studs from the later 1500-1600s?

[Braukuche]

Get the heads and case machined, probably need an oversized thrust bearing, new pistons and cylinders of course.
_________________
Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now

[mukluk]

Whynot Minot? 'Cause it's flipping cold.

[Little Car]

[Danwvw]

What about the D0 aftermarket 40 horse cases? Didn't they take a 69 stroke and came with either 40 horse openings or the later 1300, 1500, 1600 openings. I have one that's got the later openings and it's 10mm studs are inserted also it's a dual oil pressure valve case!

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!