1493cc for 1963 bug

[l3illN]

I have been lurking this forum for a while so I thought I would contribute with some details on the 1493cc build I just finished for my 1963 Bug.

Starting material is the "D" case that was in the car when I bought it in the early 90's. As far as I can tell it was a GEX rebuild. The case had been previously line bored and thrust cut. I rebuilt the engine in 1996 with a "Big Bore" kit from MOFOCO.

My goal on this obviously wasn't max power, I drive the car frequently and just wanted enough power to get up hills without gearing down quite as much as I did. I also just wanted to do it, thought it would be fun, and it is. I based a lot of decisions on the Samba and the Bill Fisher book.

Parts:
D Case
NOS 69mm OEM crank
OEM 40hp rods, big end narrowed to fit 69mm crank
Silverline main bearings and Mahle rod bearings
83mm pistons and barrels from the earlier build, not sure of the brand
AC2 reground cam from DPR Machine, 0.358 Lift 252 Duration
Silverline cam bearings
Square boss 40hp heads (yes, I know, the valves are small), 3-angle valve job, ported, 45cc chamber, 1.1 rockers. These were marked "MOFOCO" so I assume they came with the kit in '96.
Stock 1600 pushrods, shortened
Dual carbs, Italian Weber 34ICT
Custom fabricated intake manifolds for 40hp heads
3/8" ID cross over tube
Gas pressure regulator set to ~3 psi
CSP/Bellcrank type custom linkage
Doghouse oil cooler/fan shroud
019 distributor
Dansk "Sebring Style" exhaust

Notes:

I don't have a lot of miles on the engine yet with this crank/cam but I think I accomplished my goal, I can use 3rd gear all the way up the hill to my house which is not something I used to be able to do. It doesn't pull like a late model car but I think it has significantly more than a stock 40hp.

I didn't do anything to the combustion chambers, my target was 8.3 compression ratio and I was conveniently able to get there with the 45cc chambers, 0.04 deck and a spacer cut from .119 steel (SendCutSend). Un-shrouding the valves or any work in the chamber would have meant lower compression, a sub 0.04 deck or piston machining.

I currently have 135 mains, 60 idle, 160 air and F6 emulsion tubes in the carbs. This is the result of web info and driving experience. I welded a bung into the exhaust so I may buy an AFR gauge and see if the jetting can be improved.

The doghouse conversion was pretty straight forward, the D case already had the right studs and 8mm-10mm gaskets are available. I cut a hole in the stock front tin. This does make the drivers side top engine attachment nut very difficult to access. I had to make a long 17mm box end wrench to get to it from the passenger side.

I tried to save some $$ with the Dansk exhaust from CIP1. In the end I should have bought the Vintage unit. The Dansk "Perfect Fit" required cutting off the attachment points for the tips and re-welding them so the tips would come out the cut outs on the rear skirt. I am also not super fond of the sound at idle. Ignoring Buy Once Cry Once gets me, again.

The dual carb system fabrication was a fun project for the amateur fabricator. I was a little surprised no manifolds are available but I guess the obvious thing to to go with the 1300/1500 heads for the bigger valves. But these have angled ports and 40hp heads don't. Mine end up being a good conversation starter.

All the tin and bits in the engine were refinished or powder coated. For the tin color coat I used the following mix sprayed with an HVLP gun: 4 parts Rustoleum Flat Black, 1 part Rustoleum Gloss black, 4 parts Urethane enamel reducer (mostly acetone) 1 part enamel hardener. This setup looks pretty close to stock and is a fraction of the cost of automotive paint.

[petrol punk]

That looks sweet, a very nice setup. My home made dual 28PCIs on a stock 36hp pulls very well, so I wouldn't be surprised if that motor outran a stock 1600dp. Makes me want to buy a '61-'65 car to give me reason to build up my 40hp square boss head motor.
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36hp '56 European DeLuxe oval
'70 bug 1835cc

[l3illN]

Thanks, the 28 PCI is a more correct carb but way more $$. I wouldn't mind falling into a bargain on a set sometime.
My set of Webers was less than $100 in a super crusty state, I re-bushed and re-built them myself.

[EverettB]

Nice!

What is the hose on the left side air cleaner? I can't tell where it goes:

Or is that just the engine wiring harness?
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[l3illN]

Yes, that's the wiring harness.

[Rome]

Very nice work, and thinking out the combination.

Is your 69 mm crank from a '66 1300, which still has the 6 V smaller-diameter flywheel?

[RolandD]

With the right level of insanity, a a Bridgeport and a Heli-arc, it is possible to put modified 1600 DP heads on a 40hp. engine. Running 1975 L-Jetronic, it will keep up to a 1600SP in first, but falls on it's face in second.


Roland

[Alstrup]

[Alstrup]

Are you talking abbout this muffler?
https://www.autohausaz.com/images/JP-8120802100.jpg
If so, I a bit stoked as I have never seen issues with that. But I) experienced other small inaccuracies though
I´m almost certain that your probblem is due to mixing engines tranmission and body.
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https://www.thesamba.com/vw/forum/viewtopic.php?t=435993

[l3illN]

That looks like the unit.
I have a slightly wider 40hp on a 1963 chassis with a correct transaxle. This certainly shouldn't have resulted in the exhaust tips not aligning with the body notches or anything near the amount of bending, cutting and welding that I needed to do.
All that, and I still don't like the sound of it - mostly just loud.
Considering my options.

[l3illN]

Rome-

"Is your 69 mm crank from a '66 1300, which still has the 6 V smaller-diameter flywheel?"

No, it isn't. I have a newer crank and flywheel. I modified the transaxle to fit. The car has been 12V for a long time so putting a 12V flywheel in wasn't a big deal.

In case anyone is interested in ongoing work, I liked the air filter housings I made but I didn't love them. Here are a couple pics of my replacements.

I thinned aluminum tube and flared it on the press over a buck to give a "velocity stack" look. I turned a base and cap on the lathe and welded the base to the stack. The filter is protected by perforated aluminum screen.

[Rome]

Very nice custom work on the air cleaners & "necks"!

Did you try to find and install smaller venturies in the 34 ICTs to better match the "small" intake valve diameters?

[l3illN]

Rome-
I did not look at smaller venturies. There is a lot of information around on what might be the "right" size but depending on where you look the answer can change substantially.
It would be interesting, but I don't recall noting that the venturies on the Weber 34 ICT is replaceable.

[tasb]

The grey painted distributor body looks good. With the blue coil you could paint the distributor body hammertone blue which would have been color correct for a period screamer kit.

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Roads Scholar
1957 Kombi low mileage 36 hp governor equipped M 178 Slow Drag Winner 2014, 2015, 2018

1965 hardtop Deluxe Microbus owned since 1990 M 620 factory 12 v 1500cc

1961 (October)Single Cab- Road Trip Workhorse

Member# 2059

[l3illN]

I debated the painting the 019 Blue like the screamer. It was in pretty poor condition when I got it so I couldn't really tell what color it had been.
In the end, I didn't find a good match for the hammertone blue in the rattle can available locally.
Does anyone know of a good match (without telling me to search the samba)

[tasb]

This is the closest anyone has come across. It is a couple of shades lighter.
_________________
Roads Scholar
1957 Kombi low mileage 36 hp governor equipped M 178 Slow Drag Winner 2014, 2015, 2018

1965 hardtop Deluxe Microbus owned since 1990 M 620 factory 12 v 1500cc

1961 (October)Single Cab- Road Trip Workhorse

Member# 2059

[Glenn]

[RobE30]

Those filters look great! I also have a 40hp in my bug and there's not much out there to hotrod them. Gotta get creative
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1960 Ragtop bug- work in progress