Started up my freshly built motor on Sunday

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franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
I fired up my new motor on Sunday. It's a 2.0L aircooled type 1 VW engine for my Beetle.

2009_07_16.jpg

Motor

I've never built a motor before so it was a learning experience to say the least. I've never rebuilt a carburetor before and this one has two. I also rebuilt the distributor, which I'd never done either. The most impressive part to me is that it all seemed to work.


Some pics:
carb_rebuild.jpg

Rebuilding one of the carburetors

advance_mechanism.jpg

Distributor rebuild

crank_cam_installed.jpg

Mocking up crank and camshaft

shortblock.jpg

Shortblock

A boring video:
20 seconds of the 15 minute break-in run (Youtube video)


Motor specifications:

  • 2028cc
    78.8mm stroke
    90.5mm bore
    8.6:1 compression ratio
    New brazilian case, drilled and tapped for full-flow oil filtration
    Gene Berg 309 camshaft (253 degrees of duration @ 0.050")
    1.4 ratio rocker arms (0.480" total valve lift)
    Cut-to-length 3/8" chromolly pushrods
    Steve Tims Stage 1 ported and polished heads (40mm intake valve, 35.5mm exhaust)
    Port matched Gene Berg intake manifolds
    Dual 42 DCNF Weber carburetors
    Bosch Blue Coil
    Bosch VJR4BR25 mechanical advance distributor

EDIT: Added compression ratio
EDIT 2: Changed to embedded images
 
Last edited:
Demon-Xanth

Demon-Xanth

Lifer
Feb 15, 2000
20,551
2
81
Congrats on the build, it's something I still want to do at least once for the experience. I've done a lot of repair, but never a build up.
 
compman25

compman25

Diamond Member
Jan 12, 2006
3,767
2
81
What's it going into? How much HP do you expect it to make? Around 110?
 
franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
Originally posted by: compman25
What's it going into? How much HP do you expect it to make? Around 110?
Click to expand...

I'm anticipating around 100 horsepower.

It will be going in my '57 Beetle.
1957beetledeluxe.jpg
 
Last edited:
Zenmervolt

Zenmervolt

Elite member
Oct 22, 2000
24,514
44
91
Very nice.

Someday I want to get an engine from these guys for my 'teener. A nice big Type IV would be a lot of fun in an old 914.

ZV
 
compman25

compman25

Diamond Member
Jan 12, 2006
3,767
2
81
Originally posted by: Zenmervolt
Very nice.

Someday I want to get an engine from these guys for my 'teener. A nice big Type IV would be a lot of fun in an old 914.

ZV
Click to expand...

Yeah, Jake builds the best Type 4 you can get.

Oh yeah, that 57 rag is pretty nice too.
 
zerocool84

zerocool84

Lifer
Nov 11, 2004
36,041
472
126
Originally posted by: franksta
Originally posted by: compman25
What's it going into? How much HP do you expect it to make? Around 110?
Click to expand...

I'm anticipating around 100 horsepower.

It will be going in my '57 Beetle
Click to expand...

That's a hot little rag you got there. I love ragtops. My 70 has an aftermarket ragtop on it. The people I bought it from installed it in the 80's.
 
C

chucky2

Lifer
Dec 9, 1999
10,018
37
91
Careful the oil you use in there...you may need something with higher ZDDP than the normal PCMO oils out there today have.
 
franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
Originally posted by: chucky2
Careful the oil you use in there...you may need something with higher ZDDP than the normal PCMO oils out there today have.
Click to expand...

The case seen in the video is Brad Penn 30W Break-In oil. "The Green Oil"
 
C

chucky2

Lifer
Dec 9, 1999
10,018
37
91
I was thinking more long term...didn't even think to say something about a break-in oil - glad you went that route (although I don't know anything about that particular oil)...

Chuck
 
franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
Originally posted by: chucky2
I was thinking more long term...didn't even think to say something about a break-in oil - glad you went that route (although I don't know anything about that particular oil)...

Chuck
Click to expand...

The Brad Penn seems to be very strongly recommended for flat tappet cams. I've got the 10W-30 Brad Penn for here on out. My Fram (gasp!) HP1 filter lasted the 15 minutes to break-in the cam but it's out and a Wix 51515R in it's place.

I'm putting in new rear transmission mounts so I've yet to pop the motorinto the car. I should be able to do that early next week.
 
exdeath

exdeath

Lifer
Jan 29, 2004
13,679
10
81
Originally posted by: franksta
Originally posted by: chucky2
I was thinking more long term...didn't even think to say something about a break-in oil - glad you went that route (although I don't know anything about that particular oil)...

Chuck
Click to expand...

The Brad Penn seems to be very strongly recommended for flat tappet cams. I've got the 10W-30 Brad Penn for here on out. My Fram (gasp!) HP1 filter lasted the 15 minutes to break-in the cam but it's out and a Wix 51515R in it's place.

I'm putting in new rear transmission mounts so I've yet to pop the motorinto the car. I should be able to do that early next week.
Click to expand...

Might as well do them both at the same time, you'll have a hand free while putting the engine in anyway :p
 
franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
Originally posted by: thescreensavers
Originally posted by: franksta
Originally posted by: compman25
What's it going into? How much HP do you expect it to make? Around 110?
Click to expand...

I'm anticipating around 100 horsepower.

It will be going in my '57 Beetle
Click to expand...

You should get that baby polished, it will look alot better.
Click to expand...

The car?

Yeah, it hasn't had legal plates since '04. It's a real garage whore right now.
 
E

Eli

Super Moderator | Elite Member
Oct 9, 1999
50,419
8
81
Ack! Low speed break-in! Noes!

I'm all for a test run, but please tell me you're going to drop the engine into a car and do some hard 3rd gear pulls before running it any more...... :(

I used to be a believer in a gentle break-in. Not anymore.

http://www.ntnoa.org/enginebreakin.htm
 
E

Eli

Super Moderator | Elite Member
Oct 9, 1999
50,419
8
81
Originally posted by: franksta
Originally posted by: Eli
Ack! Low speed break-in! Noes!

I'm all for a test run, but please tell me you're going to drop the engine into a car and do some hard 3rd gear pulls before running it any more...... :(

I used to be a believer in a gentle break-in. Not anymore.

http://www.ntnoa.org/enginebreakin.htm
Click to expand...

You must be new to the aircooled VW world.

This is pretty much the accepted standard for engine break-in.
Click to expand...

I'm not exactly new, but I've never had one(though I've always wanted one), so I would be technically a bit of a novice.

I do, however, have extensive experience with smaller air-cooled engines.

I actually agree with his break-in analysis, though I think 100 miles is pushing it before seating the rings properly. But I digress.
 
franksta

franksta

Golden Member
Jun 6, 2001
1,967
6
81
I know this is a monster bump but it's finally installed in the car. My spare time dropped to 0 a month after I started the thread when my little baby girl was born. Now that she's about a year and a half old my spare time is returning a little.

Installing the motor was a huge fight. Everything needed some convincing to get it to fit. Then the muffler was exiting inside the fender so I cut and rewelded that.


Youtube video of the motor idling in the car and a small rev

The clutch is not disengaging completely so it's grind 'em when you find 'em in the trans. I think my cable is too long. I have temporarily stacked some washers on it and hopefully it'll be good to go at least temporarily. But I've yet to try it again. If the washers works for now I'll get a shorter cable. It's not particularly difficult to install just a bit tedious.
 
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