Oil Pump
Oil Cooler
Engine Case
Choosing a Machine Shop
Engine Case Machining Procedures
Head Rebuilding Procedures
Post-Machine Shop Procedures
Chapter 5: Component Preparation
Engine Case
Head Studs
Internal Components
Long-Block Cooling Tin
Preset the Flywheel Endplay
Scribe the Main Bearings
Gap the Piston Rings
Install the Rings on the Pistons
Crankshaft
Engine Case Preparation
Join the Two Halves
Flywheel
Piston
Barrel
Cylinder Heads
Oil Pressure Relief Valves
Full-Flow Filter Oil Pump Upgrade
Sump Plate
Valvetrain
Adjusting the Valves
Chapter 8: Accessory Installation
Important Questions to Ask Yourself
Carburetor: Rebuild or Replace?
Installing Accessories
Exhaust System
Chapter 9: Startup, Break-In, and Adjustments
Building a Test Stand
Installing an Engine on a Test Stand
Installing a 12V Starter in a 6V Transmission
Installing a 12V Engine in a 6V Transmission
Installing the Clutch and Pressure Plate
Vehicle Installation
Start the Engine
ABOUT THE AUTHOR
Prescott Phillips has been building stock and high-performance Volkswagen engines and transmissions since 1981. A semiretired Journeyman Tool and Die Maker, he always strives for perfection and has the reputation for building strong, reliable powerplants. His love for drag racing and Volkswagens led him to build some of the fastest Beetles in the Midwest. Prescott’s team, Underdog Racing, was formed in 1994 and campaigned an all-motor 11-second 1956 Oval Window Bug for many years. In 2008, Prescott built a 10-second 1960 VW Pro Stock Beetle to campaign in the ECPRA series and has done rather well. Recently, he built a 1953 street-legal Drag Bug to race in the 2017 Hot Rod Drag Week and finished the grueling 1,000-mile, 5-racetrack week with a best ET of 12.45 at 106 mph, averaging more than 20 mpg!
ACKNOWLEDGMENTS
I always thought that it would be a shame for all my knowledge of VW engines to disappear once my time on the planet came to an end. I never thought that way when I was a younger man, but when people start asking you when you plan on retiring, these thoughts become more frequent. Then, when the opportunity presented itself to actually put my decades of VW experience to print, I became apprehensive. But as the famous saying goes, “How hard can it be?” I was willing to give it my best shot.
This book was earmarked to be written by a number of other experts but never came to be. Dedication of time is a huge factor in these things. I found out through the local VW grapevine that this book had run into a roadblock. I sent an email to CarTech Books stating I’d be interested in writing a book on rebuilding a stock air-cooled VW engine. That same day, Bob Wilson of CarTech Books contacted me, and I had to convince him I was serious about writing the book and had the knowledge to put forth a good product. Kudos to Bob for his faith in me.
I’m not a photographer, and these publications need professional-quality photographs, so I went on a quest to find someone who was willing to work with me. The pay was going to be dismal and the hours long. I reached out to a couple close friends and hit the jackpot. Marybeth Kiczenski (shelbydiamondstar.com) was recommended to me. We hit it off from the very first photo session. It was a learning experience for both of us. Her professionalism and easygoing personality were the perfect combination for a successful relationship. Her enthusiasm for the project really shows. Without her help, there’s no doubt in my mind that this project would never have come to be.
My oldest brother, Peter, was instrumental in my early interest in Volkswagens. In my early teens, he was constantly working on his 1968 Beetle and left hot VW magazines lying around the house for me to pick up and fantasize about building my own Bug. The engine in this book was pulled out of his 1970 Baja Bug, and the fresh rebuild will be installed back in it after the bodywork and paint are finished. He painted my first couple Volkswagens, and I owe him so much more than just a fresh powerplant for his.
All of my friends had a small hand in the writing of this book but none more than one of my oldest friends, Peter Karempelis, or Peter K as he is known. He shared his tools and parts for many of the photos in this book. We were mid photo shoot when I realized we didn’t have some very important items to capture. A quick call to Peter K and he hand delivered them to save the day. Friends like that are invaluable and make projects like this much more rewarding.
I contacted a few VW aftermarket manufacturers and Volkswagen of America. None of them were willing to help with the development of this publication except for one. I contacted EMPI Inc., and Erica Cooper quickly responded with a “How can I help?” attitude. She provided me with all the information I asked for, and it was refreshing to know that someone in the VW aftermarket was willing to help.
Finally, I have to thank my beautiful wife, Paula. Not only did she have to put up with my usual shenanigans but the extra project of writing this book really taxed our together time. I told her I would make it up to her by taking her on vacation next year. I just need to find out what the dates are for the VW Pro Stock drag race in South Carolina.
WHAT IS A WORKBENCH® BOOK?
This Workbench® Series book is the only book of its kind on the