Aircooled VW South Africa

I have been working on the design for the new case I mentioned before. Here is a drawing so far. Im going for a 100mm stroke.

looks good. 100*94 = 2776

What are your plans regarding the main bearing size? and the method of holding down the main bearings?

Have you been to Jakes site lately? He has a very interesting engine on its way....

Very nice, but does it have its own unique cooling tinware/fan housing as well?

Tony Z wrote:looks good. 100*94 = 2776

What are your plans regarding the main bearing size? and the method of holding down the main bearings?

Have you been to Jakes site lately? He has a very interesting engine on its way....

Use superglue to hold down the bearings, it worked for valve seats on a Mazda 323, 1300cc who's head was cracked, and the exhaust vave seat came every now and then out, well that was my fathers car and he drove it for 1000's of km more, so once a month it will come loose and then he will glue it back in. that was a real "vannermerwe" car

Tony Z wrote:

This is a very interresting desing.It is not a split case,so it will be able to withstand much higher pressures,ideal for a diesel engine.

Look at teh bearing caps, they are double bolted, 2 from the top and 1 on each side of tha casing in to the bearing cap

[*]faints[*]

I dont even want to know the price of that thing once it is 'production'. Chris, your right (i think), there might just be a diesel flat-four one day. The cooling (air) is still a concern to me though.

Why go 94mm??? Go big or go home. 105mm pistons
100 * 105 = 3464cc Torque monster

A T1 replacement case wont e able to go for pistons that size.

The price tag on a 3.5l engine scares me...

Hi Guys
I made a little progress. Christmas and new years slows everything down.
I want all or as much as possible of the stock or available aftermarket parts to fit. Does not do any good to make a case which nothing will fit to. Right now I am digitizing the entire 1600 case so I can get good dimentions to work with. Make all the sugestions that you want and we will see what will fit. I know the 100mm crank will fit with just a 5mm increase in width of each side as long as the cam is dropped. 101 mm cylinders will fit if the case savers are repositioned. 105 mm might be able to fit on the case but I dont think that they will fit in the heads.. I want to have a bigger and removable oil pan too. I am pretty sure that will work.

Yes, jakes case looks nice. Knowing him the motor will cost $20,000! He will need to cross bolt those main bearings. The aluminum wont hold the pressure all by itself. I made that mistake on my 6 cylinder. I ended up making it a split case. The steel in the bolts contributes a lot to the over all ability of the bearing to remain stiff.

IF you are going to design the case to have a removable sump... why not have the cam mounted with caps instead of by the case, that way you can pull the cam out and change it with the engine still in the car.

Yes, Tony. That is already in the design. Cam and lifters will be removable from the bottom.