Engine Overhaul, Step 4

Almost there, final steps of the assembly.

A test start before installing the engine into the car, checking for oil leaks.

Cleaned bell housing and replaced gearbox mountings.

It was easy to repaint the underbody while the engine was out.

Replacing the engine compartment rubber seals.

Engine overhauled, installed and running smoothly, as new!

We'll measure the new engine output values after some running kilometers.

Some experts say that re-assembling a beetle engine is a relatively quick job taking

around 4 hours to do. According to our experience one must be prepared to spend

quite a few days with the re-assembly. We recognise that we are not professionals with

all the best tools but we did the job properly taking time to get all the details right.

Engine Overhaul, Step 3

New and old push rod tubes

New piston rings

Replacing packings on engine

Refurbished cylinder head

Assembling the engine

Engine Overhaul, Step 2

Head and barrels removed from the engine.

Head and barrels. They've seen better days..

Cleaning the piston ring grooves.

Paint stripping

Wire brush cleaning

Some of the re-painted parts.

We used high heat resistant paint for all the engine parts.

Painting and Bodywork

Beetle is finally out of repainting. The overall painting job wasn't quite the quality what we expected but as is it is adequate and what was most important, all the rusty spots have been fixed and we also replaced both of the floor boards. Everything is now fixed, the ruby red color looks good and all we wait is to get the engine overhauled and put it back to its place.

Wheels at the Vaal 2011

On Saturday 3rd September we drove to the annual Wheels at the Vaal in Vanderbiljpark. Great wide tree covered area next to a river with lots to see for the whole family; old engines, veteran tractors, vintage cars, spare parts and more. At this stage we have started to feel a bit anxious to get our bug ready and join all these other beautiful beetles at the show. But there is still couple of months to go before the work is done.

Ferdi's VW Swop Meet 2011

 Last Sunday we headed to the annual VW event, Ferdi's VW Swop Meet in Midrand. Saw lots of beautiful bugs, the original looks were especially wonderful giving great many ideas how to restore our beetle and make it look at its best. We also had the chance to go through piles of spares that were on sale. Made on feel that what you couldn't find there you won't need. If you'd want to join the fun next year please follow Motorhead's events on internet or The Big Five Events on Facebook.

Engine Overhaul, Step 1

According to "Without Guesswork, Type 1, 2 and 3" VW Service Book, August 1968 the 1300 cm2 40 bhp engine compression should be between 135-106 psi. The measured compression value was 70-75 psi which is below the specified value. Engine didn't smoke so eighter the valves were leaking or the rings were worn. Other problems discovered were that the crank case seal was leaking, the engine was very dirty and the paintwork on the engine covers and other parts was rusted.

Engine before removal

Engine removed

Before a wash. A good example of how engine should not look.

High pressure cleaning. We had to clean the engine before stripping it to prevent the dirt getting into the engine.

Engine after the wash