Restoration Project: '68 VW Beetle (o\ _!_ /o)

[AsadIshaque]

The two crankcase halves' outer view.

Note that some of the cylinder head studs have come off while dismantling. These and a few others would need repair by the machine shop as they must be held on very tight.

Machine shops here enlarge the existing bores on the case and run a tap. The studs end is treated as follows.....some material is built upon it by a series of electric welds and then a new thread cut over on it. The oversize threads are then screwed into the case.

Above is not a standard repair. Its something us desis have come up with.

We shall aim to go for the standard. Insertion of a 'helicoil' to bring the threads to spec. Last time I checked, no one was willing to do it. This time Id look harder and try convincing the machine shop to comply.

Wish us luck please. We need loads of it

[murtaza_murti]

@AsadIshaque, I am speechless. I don't know how to thank you enough for helping me out with this project and taking your precious time out for the Bug throughout every phrase of the process.

I've been really busy over the past two days with my research paper, writing 5000 words and explaining each and every detail isn't as easy as I thought it would be.

I am sorry I couldn't come over to the workshop on Friday. I'll definetly go the workshop tomorrow during my class break from 1-3pm. I'll call you in while and make a plan.

[AsadIshaque]

You are most welcome!!

As you can see, pleasure was mine

Tearing down an engine is a learning experience. All the more better if its a VW engine. If one has the eye and a brain, you can decipher what the metal parts tell you. Who said only humans have a tongue to talk?? They have a story to tell, what went wrong where and how. The use, abuse and yet more abuse.

I have a double duty tonight. Shall be getting off tomorrow early evening. Most probably I'd only manage to head back home, barely, with a drunkard's gait. If by chance I have the energy left, I'd visit the garage.

The plan for tomorrow at the garage is to wash and clean everything down. Then most of the parts shall be taken to the machine shop for a good inspection and his verdict on what is fit to reuse.

You may pay a visit at lunch break to show them your interest. Don't be late for your classes as studies are top priority, please remember that.

Ive put down everything in detail for people to see here and learn a thing or two. Above all, I want everyone to see what an abused VW's engines internals are like. Its a lesson for not letting an idiot overhaul your precious rides engine.

At this time, Id salute the VW faithful air cooled flat four for enduring so much use, abuse, hardship and plain incompetent workmanship during a rebuild and even then having run for so many miles.

Off to work now, before I get late.

[murtaza_murti]

You are most welcome!!

As you can see, pleasure was mine

Tearing down an engine is a learning experience. All the more better if its a VW engine. If one has the eye and a brain, you can decipher what the metal parts tell you. Who said only humans have a tongue to talk?? They have a story to tell, what went wrong where and how. The use, abuse and yet more abuse.

I have a double duty tonight. Shall be getting off tomorrow early evening. Most probably I'd only manage to head back home, barely, with a drunkard's gait. If by chance I have the energy left, I'd visit the garage.

The plan for tomorrow at the garage is to wash and clean everything down. Then most of the parts shall be taken to the machine shop for a good inspection and his verdict on what is fit to reuse.

You may pay a visit at lunch break to show them your interest. Don't be late for your classes as studies are top priority, please remember that.

Ive put down everything in detail for people to see here and learn a thing or two. Above all, I want everyone to see what an abused VW's engines internals are like. Its a lesson for not letting an idiot overhaul your precious rides engine.

At this time, Id salute the VW faithful air cooled flat four for enduring so much use, abuse, hardship and plain incompetent workmanship during a rebuild and even then having run for so many miles.

Off to work now, before I get late.

The engine is the most interesting thing in a Bug. I'll go and have a visit to the workshop in the lunch break for sure, would probably take pictures aswell. Yes, indeed the poor engine suffered alot but didn't die on me at all when I brung her home.

See you later, please text me when you have time to talk. I will give you a call then.

[nmshaikh]

The intake manifold with the carburetor still on.

This has seen some serious abuse. One leg of the heat riser cut off. People just do not understand the function of this and consider it an 'extra' like so many other things on a beetle. For such people, castration of their right nut is suggested since that is an extra too The left would function just as well.

One can see a couple of areas from where LPG was fed into the engine. Some serious hammering took place, God knows why, to the area where the carb sits. Check out the creases.

Shall resume posting in a while. Interval in the horror-fest special.

@Asad. Why stop with at right nut? Why not both the right and the left ?
The gene pool can do well without. technically they would still 'function', like this poor beetle did with the heat risers cut off.

[nmshaikh]

The fly wheel.

I dont know why, but people often call it a "FRY" wheel

Anyone who does, please stop being an idiot. You cannot fry anything in this wheel, except your clutch plate if you don't know what to do with your left foot while driving.

Given the amount of oil present on the clutch surface and the flywheel itself..it should be called 'deep fry' wheel.

[nmshaikh]

Note the use of RTV silicone gasket sealant to join the cases. The VW engine should NOT be sealed with this crap. Unfortunately its a hot favorite with the local mechs who find it a band aid solution for everything.

Silicone is used as the silly cons use a screw driver or simillar tool to seperate (split) the crank case open when tearing down therefore necessitating the use of silicone to prevent leaks. if the two surfaces are not suffering any damage they should only receive a thin layer of Curil and nothing else.

[mohsinikram]

Silicone is used as the silly cons use a screw driver or simillar tool to seperate (split) the crank case open when tearing down therefore necessitating the use of silicone to prevent leaks. if the two surfaces are not suffering any damage they should only receive a thin layer of Curil and nothing else.

what is the possibility of finding a NOS engine for my Beetle 1131 cc far fetched but I wouldnt be surprised if I come across one.

[nmshaikh]

@Mohsin,

NOS complete engine, maybe not..however you can find NOS components to put together a decent engine. I do have a complete 25 hp engine for an early split /oval but the challenge is getting it across. I just bought a NOS German muffler for an Oval which would also be right for your car (single tail pipe) You are welcome to have it. I also have almost everything NOS to rebuild a 25hp..just ask. Did you get the original engine withthe car? It would be great if you have a matching numbers engine that is correct for your car and i would strongly recommend you rebuild such an engine to maintain the integrity of the car.

[AsadIshaque]

@Asad. Why stop with at right nut? Why not both the right and the left ?
The gene pool can do well without. technically they would still 'function', like this poor beetle did with the heat risers cut off.

Sure wish I could do that :P, with the facilities I have at hand at my work place, it IS very much a possibility (A)

[AsadIshaque]

what is the possibility of finding a NOS engine for my Beetle 1131 cc far fetched but I wouldnt be surprised if I come across one.

May be a very very remote possibility abroad. A couple of years ago, some long forgotten type 3 engines were discovered in quantities sizable enough that one of the popular parts website sold them as 'limited stock'. They were gone on no time at all.

Parts for these early engines are very hard to come by. Locally, you'd be lucky even if you get a single bolt.

Mohsin bhai, I must very earnestly say that I strongly recommend you get your split's engine rebuilt by a guy well trained in VW matters (by well trained I mean enough to know his $hit about VDubs and not having done a couple of overhauls in his life making him think he's an 'ustaad'). Yes anyone can overhaul a Dub motor but few can do it right.

This engine is screaming testimony of the fact that one must never let 'conventional' mechs come near these. They are simple, wonderfully simple but often screwed up by mechs who think they know all.

In my years of VW ownership, I learnt this fact through experience, bitter experience in my early days. Good lessons learnt that Id never forget.

[AsadIshaque]

The cylinder heads we pulled off the motor had a part number which lead me to think they were for a 1600cc application. (Which seemed funny since the cylinders looked 1300cc eyeballing them. Of course, measurements would have confirmed).

Thats what one of my books said.

Researched it today and learnt new things. The same part number holds for both the 1300cc dualport and 1600cc dualport heads. Funny. The way of differentiating them, I'd explain with pics once I snap a few more.

[AsadIshaque]

@Mohsin,

NOS complete engine, maybe not..however you can find NOS components to put together a decent engine. I do have a complete 25 hp engine for an early split /oval but the challenge is getting it across. I just bought a NOS German muffler for an Oval which would also be right for your car (single tail pipe) You are welcome to have it. I also have almost everything NOS to rebuild a 25hp..just ask. Did you get the original engine withthe car? It would be great if you have a matching numbers engine that is correct for your car and i would strongly recommend you rebuild such an engine to maintain the integrity of the car.

Unfortunately, the split came without the original engine. Id share the story on the split thread, what I know.

Mohsin bhai has a 1958-59 vintage 36Hp motor which came with the car. I think we must overhaul that with utmost care and try to source as much of the good stuff for it as possible.

What do you say Mohsin bhai???

[AsadIshaque]

Shall update this thread in a day or two......

The engine bits have been picked up from the machine shop after a struggle to get things right from his end.

[Xulfiqar]

May be a very very remote possibility abroad. A couple of years ago, some long forgotten type 3 engines were discovered in quantities sizable enough that one of the popular parts website sold them as 'limited stock'. They were gone on no time at all.

Parts for these early engines are very hard to come by. Locally, you'd be lucky even if you get a single bolt.

Mohsin bhai, I must very earnestly say that I strongly recommend you get your split's engine rebuilt by a guy well trained in VW matters (by well trained I mean enough to know his $hit about VDubs and not having done a couple of overhauls in his life making him think he's an 'ustaad'). Yes anyone can overhaul a Dub motor but few can do it right.

This engine is screaming testimony of the fact that one must never let 'conventional' mechs come near these. They are simple, wonderfully simple but often screwed up by mechs who think they know all.

In my years of VW ownership, I learnt this fact through experience, bitter experience in my early days. Good lessons learnt that Id never forget.

same with old mercedes engines

[AsadIshaque]

^^

Xulfiqar,

Pl give us your views on what we should aim to buy to help put Humpty Dumpty (our engine) back together again.....

The two of us plan to go visit the old city sometime to collect the wanted glues and stuff to use while putting the engine back.

Our mech uses 'Curil' and 'Shellac' to put the case together. What else do we source??

[AsadIshaque]

Now for some updates guys.

The Machine Shop experience was a very bad one. I had chosen the shop reputed to be the best in Karachi. Hah! The problem here is the best thinks he is the best but its otherwise. Anyway. Perpetual problem in Pakistan, unfortunately. 

 Had to make many rounds of the Machine Shop with me pointing out thing after thing 'left untouched' by the machinist. Incompetent fools. This led to many delays, wasted trips, frustration and flying tempers.

[AsadIshaque]

I managed to dig out (and what a dig it was :) ) German main, big end and Camshaft bearings. These are the very life of an engine and definitely much better than the Brazilian stuff. 

Above is the pic of the big end bearing box. Could not take pics of the main bearings and Camshaft bearings boxes. They are all by "Kolbenschmidt", an excellent German manufacturer.

Good stuff :D

[AsadIshaque]

The crankcase/engine block...... after it was received from the machine shop, it got a lot of TLC, namely gentle scrubbing to take off the silver paint and crud. VW crankcases must NOT be painted. If anyone tells you otherwise simply brand him an idiot and dont listen.

Even with all my effort with the machine shop, we discovered after a thorough test that one of the cylinder studs still needs repair. We plan to get to it in a bit.

The 'case was align bored too to make the crankshaft sit in well and true. many studs had to be repaired or replaced.

The 'case still has to be pressure washed and all oil galleries (tubes and ducts thru which engine oil flows in the engine) cleaned out and checked.

[AsadIshaque]

The new crankshaft. This was on its first undersize. The Machinist took it to the second undersize 0,50mm in VW speak.

This crank is much better than the original having larger oil passages for better lubrication. The engine can easily be upgraded to a 1500 or 1600cc if need be.

The flywheel was test fit to the crank as you can see. The flywheel itself was 'faced' and checked so the Clutch and Pressure plates function well. The teeth were a bit worn on the flywheel but we hope it causes no problems down the line.