Let's learn together Series
For the passion of the details. Learning together and passing on to the next Generation the Craft of Vintage Engine Building
Videos
Part 5: Porting the case for a Mini-Stroker (74mm - 76mm)
Part 4: Cleaning the oil galleys
Part 3: Building a VW Touring Motor (Premium Edition)
Part 2: IDF Dual Carbs history & mods
Part 1: IDF Dual Carbs & Fuel Systems
Drag Racing TV: VW Engine Building Series
VW Engine Building: Disassembly, Type 1, 1500-1600cc
Aircooled Volkswagen Type 1 engine building video: Tearing down a used VW engine. Mike Smith shows why it's important to watch out for issues when taking apart a used VW engine, that's going to be rebuilt.
VW Engine Building: Case Evaluation, Type 1, 1500-1600cc
Aircooled Volkswagen Type 1 engine building video: Case evaluation. Mike Smith shares some great info on how to identify problems with used VW engine cases.
VW Engine Building: Crank & Rod Assembly, Type 1, 1500-1600cc
Aircooled Volkswagen Type 1 engine building video: Crank and rod assembly. Mike Smith shows how to heat up the gears and get them installed on the crank, in the right direction. The VW nose bearing needs to line up correctly, because it has a dowel pin hole, that matches up with the dowel pin in the VW case half. Mike then covers rod/rod bearing install onto the VW crank. Even if you've used Plastigage or whatever to measure the clearances, the rod still might hang up on the crank, as illustrated here.
VW Engine Building: Assemble Short Block Part 1, cam, crank, lifters
Aircooled Volkswagen Type 1 engine building video: Assembling the short block, Part 1. Mike Smith starts off this segment by going through all of the items in the engine gasket kit. He covers differences in engine cases that relate to the gaskets, and shows how to install various o-rings, camshaft bearings, crank bearings, and lifters. This section is critical, because it's real easy to get the crank bearing off center when it's dropped into the case half. The VW crank bearing dowel pin holes must line up with the pins in the case half. Mike Smith also covers the various VW camshaft gear designs in this VW engine building video clip.
VW Engine Building: Assemble Short Block Part 2, oil pump, end play, Type 1
Aircooled Volkswagen Type 1 engine building video: Oil pump identification/install and putting the VW case halves together. Mike Smith also covers setting the end play on the Type 1 flywheel.
VW Engine Building: Heads, Valves, Springs, Keepers, Type 1, 1500-1600cc
Aircooled Volkswagen Type 1 engine building video: Cylinder head evaluation and installation. VW engine guru Mike Smith covers possible issues with both new and used VW heads, including showing us some examples of cracks in used VW heads. Valve keeper installation and issues are illustrated. He shows how to lap valves, and how a lapped VW valve compares to a new unlapped valve. Assembly of the valves, springs, and keepers is covered here. .
VW Engine Build: Top End Install Part 1, compression ratio, pistons
Aircooled Volkswagen Type 1 engine building video: Top End Install Part 1, Type 1, 1500-1600cc. In this segment, VW engine building guru Mike Smith shows how to measure the combustion chamber volume inside the head, in order to calculate the compression ratio of the engine. Other subjects covered here include proper positioning of the piston rings inside the jug, and assembling the piston/piston pin/jug on the rods. The deck height of the VW engine is also measured here, and that volume is included in the compression calculations.
VW Engine Build: Top End Install Part 2, shims, jugs, rockers, Type 1
Aircooled Volkswagen Type 1 engine building video: putting shims under the jugs, installing the cylinders over the pistons. Mike Smith also covers the differences between 8mm and 10mm VW head studs, with respect to when it comes to installing the cooling sheet metal under the jugs. He installs the push-rod tubes, and heads. Defective worn out rockers are shown in detail, so that you know what to look for.
VW Engine Build: Final Assembly Part 1, distributor drive gear, Type 1
Aircooled Volkswagen Type 1 engine building video: Final Assembly Part 1 of 4, distributor drive gear installation and valve lash setting. Mike Smith shows how to install the drive gear slug correctly, making sure that it's coordinated with the valve timing and the mark on the front pulley of the engine. He also shows how to set valve lash on the VW aircooled engine.
VW Engine Build: Final Assembly Part 2, Oil Cooler Seals, Type 1
Oil Cooler Seal faq, aircooled Volkswagen Type 1 engine building video: Final Assembly Part 2 of 4. The VW factory released several different single-port oil coolers, and there are also differences in oil galley sizes in the various versions of VW engine cases. There are four different types of oil cooler seals, one of which is for Type 3 VW squareback engines. Putting the wrong seals on the wrong cooler can cause major problems. Mike Smith goes over all of the possible situations in detail; his expertise here has created the definitive VW Type 1 oil cooler seal faq.
VW Engine Build: Final Assembly Part 3, flywheel & sheet metal install
Aircooled Volkswagen Type 1 engine building video: Final Assembly Part 3 of 4. Mike Smith installs the front pulley, dual port intake manifold, and dual port fan shroud. He then covers flywheel installation and torquing down the gland nut. Remember to always have some kind of lube on the gland nut, for instance, if you are setting end play on the rear main bearing. Don't tighten dry threads down against each other.
VW Engine Build: Final Assembly Part 4, clutch & pressure plate, Type 1
Aircooled Volkswagen Type 1 engine building video: Final Assembly Part 4 of 4. Mike Smith goes over clutch and pressure plate installation. The break-in procedure for your new engine involves removing the spark plugs and rocker arm assemblies, then cranking for oil pressure until well after the warning light goes out. Squirt the valve stems and springs with oil before putting the rocker arm assemblies back on. You are now ready to start the engine for the first time. Do not let the engine idle at all during the first 5 or so minutes of operation. You should hold it to somewhere around 2,000+ rpm during this period. It never hurts to change the oil after this initial startup, but you must re-adjust the valves after the engine has cooled overnight. Your next oil change and valve adjustment should be no later than 500 miles down the road. These are the minimal engine break-in requirements, see the Gene Berg written material for a more complete procedure.
DuneBuggy Warehouse - Videos & Tech Tips
How To Inspect Your VW Type 1 Engine Case - Air-Cooled VW Tech Tips - The Oil Leak EP2
If you're looking to re-use your VW Type 1 Engine Case, build a monster race motor with a donor block, or you're hunting for a used engine or engine block at the next BugSwap event, here is one of the most thorough tutorials on how to inspect a VW Type 1 engine case. You can read this article on our website: How To Inspect Your VW Type 1 Engine Case – DuneBuggyWarehouse.com
How To Measure a VW Type 1 Engine Case for Main Bearings - Air Cooled VW Tech Tips
Here's a quick tech tip showing you how to measure your VW Type 1 engine case for main bearings. See ALL the engine bearing measurements in our Main Bearing Size Chart here: https://dunebuggywarehouse.com/blogs/...
This is a 'quick and dirty' method showing where you need to measure. A bore gauge on a torqued engine case will always be the most reliable way to measure, but this video will help if all you have are dial calipers. VW's wear limit on case bore is +0.001" but as a general rule, your bearings should snap into place and fit snugly with the case halves torqued. If your bearing fits loose it may be time for an align bore.
How To Tell Which Spark Plugs You Need for Your Air-Cooled Volkswagen Bug - Dune Buggy Warehouse
Have an air-cooled VW Beetle, Dune Buggy, Bus, Baja, Sand Rail, Ghia, Type 4 or Type 3? Need to know which spark plugs will fit it? Check out this quick video showing the most common plugs used in different air-cooled VW applications.
Air-Cooled Volkswagen Electronic Ignitions 101 - for VW Beetles, Buses & Dune Buggies
Here's a quick guide on electronic ignitions versus points for air-cooled VW beetles, dune buggies, VW buses and Type 3s. We cover how to prevent problems with them, testing coil resistance and the differences between points and electronic ignition. Our goal is to help you make a choice that suits you and your air-cooled ride the best.
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