JBugs - 1600cc Engine Build Series - Part 1

JBugs - 1600cc Engine Build Series - Part 1 - Short Block

Рет қаралды 37,597

Күн бұрын

View our complete selection of air-cooled VW parts on the JBugs website: www.jbugs.com/
We've had this video planned for some time and finally got to it, although based on the struggles Sam had while building this engine, perhaps we should have waited a bit longer! Either way, Sam got the engine built after a few mistakes during the build process. Follow along and watch the steps Sam takes, and the mistakes he makes while building this all new, EMPI Unassembled Long Block 1600cc engine.
EMPI's Stock 1600cc Engine Kit comes with everything you'll need to build your own Type 1, 2 or 3 VW long block. The engine kit includes a new aluminum Universal engine case, a 69mm 4140 Chromoly Crankshaft, forged stock connecting rods, a stock camshaft, dual port cylinder heads, chromoly pushrods, solid shaft 1.1:1 rockers with swivel ball adjusters, a 26mm Schadek Oil Pump, chromoly head studs, Mahle Rod Bearings, Silverline Main Bearings, Cam Bearings, a complete Elring Engine Gasket Kit (although ours was missing the sump plate cap nut sealing washers), 12 Volt Flywheel, valve covers and bales, and most all the hardware needed to assembly your new 1600cc VW long block engine.
A few extra pieces will be needed to complete the engine, such as flywheel shims (available in a kit here - www.jbugs.com/type-1-1300-160...) but you'll use only 3 pieces to set the crankshaft end play. Also, our engine gasket kit was missing the sump plate cap nut sealing washers, but that is not typical, that was Elring's mistake in packaging the gasket kit.
Intro: 0:00
Parts breakdown: 0:59
Word of advice: 03:35
Parts cleaning: 04:58
Initial crank end play check (with timing gear prep): 06:54
Timing gear installation: 10:19
Connecting rods installation: 13:48
Engine case prep: 17:36
Crankshaft installation: 23:33
Camshaft prep: 28:09
Camshaft installation: 28:28
Case half prep: 28:40
Case half installation: 31:05
Oil pump installation: 35:10
Oil sump plate installation: 36:53
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Parts used in this video:
www.jbugs.com/product/98-0470... - Unassembled 1600cc Long Block
www.jbugs.com/product/5770.html - 36mm Gland Nut Socket
www.jbugs.com/product/5714.html - Distributor Drive Gear Puller
www.jbugs.com/product/5015.html - Engine Stand
www.jbugs.com/product/5124.html - Gasgacinch
All parts used in this video are available at: www.jbugs.com/
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Facebook - / jbugsvwparts
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Music Provided By:
Keep It Real by Audionautix is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Artist: audionautix.com/
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Videos are intended for entertainment purposes. Factory specifications should be followed when performing any task on your vehicle.

Пікірлер: 71

@mish4776 9 ай бұрын

Im glad you showed the messups you made cos it shows the build in real life so people doing it for first time can get it right

@w2tty 9 ай бұрын

I like this video. It’s tiring seeing all the perfect videos out there. It’s so much better to see reality. Thank you.

@Sam_Mebane 9 ай бұрын

Agreed, mistakes happen and with editing anything can be made to seem like it was perfect. In reality though things rarely go exactly as planned and we figured showing the mistakes and how to fix them would be much more helpful!

@kevincherry9712 25 күн бұрын

I'm glad you showed the rods getting installed backwards, I too did that and didn't catch it. Couldn't understand why it kept throwing the flywheel off the crank. Never made that mistake again!

@JCromheecke Ай бұрын

great video! Im glad im not the only one who made the same mistakes with my first engine build.

@Sam_Mebane Ай бұрын

To err is human, to forgive, divine. I'm not here to show how perfectly everything goes, if I make a mistake, I'll show it, and how to fix it!

@markzurlo1787 5 ай бұрын

Great Job, I'm glad you showed the ups and downs of this build. Real-life problems are better seen than just talked about.

@Sam_Mebane 5 ай бұрын

Thanks for the encouragement Mark!

@VolksStokes Ай бұрын

Watching this was like a therapy for me 😅. Thx Sam for another awesome clip

@Sam_Mebane Ай бұрын

My pleasure Volks!

@protodog1 4 ай бұрын

Better have a talk with your shipping dept about having to eat the case. Put the case box in a larger box with plenty of packing. Worth the extra shipping cost. Page 120 in "How to Hot Rod VW Engines: The best procedure for building any engine is patience, care and constant rechecking" When I built my first engine at 15, I put a couple main bearings in wrong. That was my learning curve.

@sshaw7912 4 ай бұрын

That's what I have always been afraid of doing this myself. If it was a sb Chevy or Ford I wouldn't have a problem. But VW completely different. My engine builder won't be available till later this year.

@yewboup1 9 ай бұрын

Thanks for that unvarnished look at assembly. I prefer the honest videos.

@Sam_Mebane 9 ай бұрын

It is a heck of a lot easier to show the mistakes than to hide them!

@thumbbro8977 9 ай бұрын

PERFECT timing! I was just considering rebuilding the engine on mine, so this'll be an enjoyable time.

@Sam_Mebane 9 ай бұрын

As long as you aren’t filming it, it should be!

@Medichell69 9 ай бұрын

I hope you had as much fun as we all did watching! We’ve all been there! Great content brother!!!

@Sam_Mebane 9 ай бұрын

I can’t say this one was “fun”’ but in hindsight it wasn’t too bad!

@imderrickjed 9 ай бұрын

Its a great video. I started out with hope when you said its as easy as legos. In the end you talked me out of buying one. So thank you for saving me the stress.

@Sam_Mebane 9 ай бұрын

Even Lego kits can be built incorrectly! Fortunately just like Legos all you have to do is pull a few pieces and put them back together. Keep in mind, I was doing this on camera, for the audience to see, and explaining this as I went along. When you have a clear space and can concentrate on the task as opposed to explaining the task it is much simpler!

@projectinlinesix 9 ай бұрын

THANK YOU so much for doing these videos!

@Sam_Mebane 9 ай бұрын

It is truly my pleasure although this engine wasn’t exactly a pleasure to build!

@eduardorodriguez3262 9 ай бұрын

Happy Friday! Great build video now i can go to work👍🇩🇪

@Sam_Mebane 9 ай бұрын

And I got to say hello to you there again!

@sigungajoshua6149 Ай бұрын

Boxer Beauty With A Touch Of Madness.

@davidsanderson3902 6 ай бұрын

great content - really felt your pain when you put the engine case together and the crank kept getting pinched

@Sam_Mebane 6 ай бұрын

It truly was! The video doesn't do it justice but I wasn't going to show 30 minutes of going back and forth with it!

@YakyuBoy 9 ай бұрын

Nice video, thanks for the upload. Makes me feel like I can do this someday

@Sam_Mebane 9 ай бұрын

It isn't hard...when you aren't trying to explain it and film it for someone else!

@chesterumana9779 9 ай бұрын

Excellent 🎉

@rasdavis8390 5 ай бұрын

Great stuff🫡💯🖤 u done good sir not to worry shouts from England 🇬🇧

@bryanmeade7327 6 ай бұрын

Great video. You're human. Enjoyed it!

@Sam_Mebane 6 ай бұрын

Thanks Bryan, to err is human, to forgive is divine!

@gr2262 4 ай бұрын

33:15 "what the FUNK" great to keep it Christ-like brother! 😂 loved the videos... looking forward to meeting you

@Sam_Mebane 4 ай бұрын

Hahaha, absolutely. Do not let any unwholesome talk come out of your mouths, but only what is helpful for building others up according to their needs, that it may benefit those who listen.

@ottolinden371 9 ай бұрын

Great video but I'm a little confused, the title says short block but you say long block? I'm pretty new to VW's not sure what the difference is :)

@Sam_Mebane 9 ай бұрын

A short block is the assembled case halves with the connecting rods sticking out either end. A long block is a fully assembled engine (minus the accessories like engine tin, etc.) with the cylinders and heads bolted in place.

@josephheston9238 9 ай бұрын

If I got that case with a chunk broke off in that spot, I’d just TIG weld it back. No harm, no foul. BTW, I thought they came with the case savers installed. Speaking of the case savers, are they for 8mm or 10mm studs?

@Sam_Mebane 9 ай бұрын

The broken piece isn't in a place that matters so we'll just leave it as is, again, no harm, no foul! The 8mm case savers were loose in this kit.

@thestove2407 4 ай бұрын

Great video Sam Learning "how not to do things" ... is an important component of collateral learning. Cheers

@Sam_Mebane 4 ай бұрын

Absolutely, the biggest part is not being afraid of failure! I've failed more times than I've succeeded in most everything, I'm still learning as I go!

@ctreatman Ай бұрын

Sam, are the cylinder heads complete and ready to bolt on or do the valves need to be lapped before installation?

@Sam_Mebane Ай бұрын

The heads are complete and ready to run. Could they be pulled apart and get a full 3 angle valve job? Sure, but I've never bothered for stock applications.

@dangrover12 2 ай бұрын

What is torque of the center big nuts? Jbugs site says 18lb other places say 25. With my halves together 18 lb its free to turn and if i go 24 it it very hard to turn. Is it still ok if i can turn at 18?

@Sam_Mebane 2 ай бұрын

15, 20, then 24 foot pounds in steps through the torque pattern.

@dangrover12 2 ай бұрын

What was the final problem that finally solved your locked up crank? Too you a few times. Not the rods being upside down but when torqued crank locked. I am having that problem. 4 times now tighten middle 2 just a little and it locks up

@Sam_Mebane 2 ай бұрын

The bearings weren’t settled in place on the dowel pins. They are finicky little things!

@67VWForever 9 ай бұрын

I had the same issue with that stupid front bearing too..

@Sam_Mebane 9 ай бұрын

The struggle is real, stupid little dowel pins!

@mohdrhaiz8146 7 ай бұрын

1. What's the effects if Rod are backwards 2. Always see people grinding a pathway for the middle bearing to help with oil flow. Is this necessary

@Sam_Mebane 7 ай бұрын

The rods are machined to be installed one way, I'm not sure if it is the oil passages, the balance or offset or who knows what. Either way, they are supposed to be in one way, so that's the way I installed them, eventually! Machining the center oil passage isn't necessary, millions of VW engines were done without it and plenty of them are driving around that way still. Bob Hoover came up with a number of oiling improvements through his years of research and working on VW engines for use in airplanes. The VW engineers did great on designing the engine and in stock form, it is fine the way it is, but there is always room for improvement when it comes to adding horsepower and performance.

@billoneill3636 6 ай бұрын

Does Jbugs offer in house classes for "hobby" VW restoration? I've looked on line, and there is nothing out there. Would be great to have the opportunity to spend a week and have a better understanding of electrical, mechanical and body work. These videos are great, but to have the hands on experience would be valuable.

@Sam_Mebane 6 ай бұрын

No, and for liability reasons it probably isn't something that we'll be able to do. We've regularly seen VW clubs put together "wrenching" or "shop" days which would probably be the closest thing we can think of.

@ctreatman Ай бұрын

Hey Sam. What gasket compound do you use for the oil pump gasket?

@Sam_Mebane Ай бұрын

Gasgacinch typically, although copper RTV works well, as does Permatex Aviation Sealant.

@ctreatman Ай бұрын

@@Sam_Mebane sweet! It's good to know there are options on that. Thanks!

@CornChowder809 6 ай бұрын

What was preventing the crank to spin?

@Sam_Mebane 6 ай бұрын

Best I can tell is that when I pulled the case half off the first time to remove the o-rings for the shuffle pins is that one or more of the bearings shifted on the dowel pins. Making sure the bearings are aligned is probably the most difficult portion of assembling the bottom end.

@chrisfreemesser5707 9 ай бұрын

The struggle is real Sam 😉 What do you use to seal the two case halves? Seems like an ideal place for a leak to happen

@Sam_Mebane 9 ай бұрын

I use Gasgacinch, always seems to work well for me.

@calescapee9642 5 ай бұрын

You can use permatex aviation sealant

@Sam_Mebane 4 ай бұрын

@@calescapee9642 Aviation sealant is a little thick for the case halves. I love it and use it just about everywhere, but just not for the case seam.

@TheOsolito 5 ай бұрын

Very nice video how much will cost to buy a kit like that ty

@Sam_Mebane 4 ай бұрын

@TheOsolito - www.jbugs.com/product/98-0470-B.html

@vintage76vipergreenBeetle 9 ай бұрын

👍

@p51bombay 6 ай бұрын

Packaging suggest most of that stuff is made in China or similar

@Sam_Mebane 6 ай бұрын

Just like the computer and keyboard I'm typing on, the smart phones we use daily and so many other things... Just because it is made in China doesn't mean it can't have quality. Look at Apple iPhones, computers, etc. When suppliers demand quality out of their manufacturers as opposed to just asking for an inexpensive price, China is completely capable of supplying parts that are more than up to the task.