40HP Volkswagen engine big bore build

This 1200cc 40hp Volkswagen engine from about 1965 was sitting in a field outside Sacramento, California for at least 15 years. When I checked the compression, I found it had a hole in the No 3 piston, which meant a total teardown. Here's a 5 minute video of me putting it all back together and running it for the first time. Enjoy!

[@Wallace459]

I rebuilt and drove these engines from 1968 until 1994. At the end of that time I was up to 1700cc's but I still used a single carb and an 09 distributer. I really miss the simplicity of those vehicles.I enjoyed the video. Thanks!

[@mrmark0247]

How can i get its engine?

[@aguilayserpiente]

010 here.

[@johnmartin2079]

Hell yeah, I can't imagine how many of those engines were piece milled together by us kids in the 80s, Newport Beach, Costa Mesa, Santa Ana, Anaheim. Calli. Bug ins of the 80s. Right on brother.

[@leonardvernon7176]

Wish I was with all of you!

[@_IMNNO]

OC gang

[@jlr3636]

The most versatile engine ever designed. My first build was a 1200cc into a 1776cc, next was 1300cc into a 1835cc, then two 1600cc, then mostly aftermarket parts into a 2180cc,my last was a monster 2275cc dual 48IDA Weber carb, counter balance forged crank, that thing would haul ass. Pre ran the Baja 500 course with the 1835 in a Baja Bug.

[@davidcarter9940]

I rebuilt one of those when I was 15 years old so it was ready for when I turned 16. This brings back memories of many hours in my Dad's shop. Thank you.

[@NoosePaper]

This is an amazing video! Never seen such care and attention made for an air cooled Volkswagen! Simply fantastic, great work!

[@harshakarunaratne9581]

Newly overhaul Volkswagen engine is fully done with brand-new parts up to the Showroom condition. Anyway thanks for displaying the entire story in a perfect maner.

[@vredewold]

Watching a piece of art being put together again. Then she purrs like a kitten. So smooth. My Käfer from 1968, which I drove when I was 18y. old 1979 never ran so smooth. Although she was well serviced, totally original 54688 miles. So high tech also works on an enige first developed in 1938 (Typ 1) I bow for you.

[@donaldbrittsan984]

Finally someone who knows how to time a VW the right way 👍

[@67Oldvolks]

You make it look so easy and effortless. Great video!

[@NebulaTraveler2956]

Such a nice work, beautifully filmed and explained - everytime wonderful to see how a bunch of parts come to a running engine...

[@jimmyjimjimmyjimjimjimjim4437]

This takes me back. I rebuilt so many of them back in the 70's I lost count. The last one was an 1800cc big bore, with a Holley carburetor in a Karmen Gia. If I remember right, we had to machine the case to fit the cylinders. That motor sucked so much air that the intake manifold would be covered in ice for the first 10 minutes. Fun times.

[@jebsails2837]

BITD. In the late 60's myself and 3 friends all had "Vdubs". We were looking for any additional edge. One trick was larger carb jets from an MB-Solex (?). My favorite was knocking the packing out of the stock exhaust tips using a socket and 3/8 drive extension bar. Thanks. Narragansett Bay

[@johnspathonis1078]

I wish I had your engine stand when I rebuilt my 1954 VW. Great video. Brought back a lot of memories.

[@RantzBizGroup]

Great video, most folks never see air cooled engines, other than motorcycles, being rebuilt.

[@rayoflight62]

This made me recall how many times I worked on the engine of my Beetle - the model from 1973, the one with big rear lights. Thank you for posting...

[@julianodalolio]

I don't know about Los Angeles, but here in Brazil this type of engine is 1300cc!! here in Brazil to be a 1200cc 1st the fuel pump came next to the oil switch 2nd the dynamo support were fused to the engine block. but a nice job was done on this engine congratulations

[@jamesteeple6984]

One of the best tutorial videos I've seen amazing work

[@albertogonzales3536]

El legendario motor VW. Cuántas generaciones hemos pasado por esta hermosa creación Germánica

[@THOMASS_P]

I just rebuilt a 1500cc into a 1600cc first time. Full tear down also..got it running last friday 6/10, MAGIC

[@marcusbrown1767]

Does your shop do these repairs for fun or business. My 1500 needs a bit of work.

[@beabetteryou2022]

The beauty of simplicity

[@HandleCarefully925]

I still love those engine. Will always be a masterpiece 🤩

[@nicholaskennedy4310]

Nice Vid! Old VW guy here..Love the sound!

[@mechcntr7185]

Excellent video! Keep up the good work.

[@denzelkhonje4759]

I haven't seen something beautiful like this in sometime

[@VWPrince53]

Awesome job rebuilding it! Sounded great! Thanks for sharing! 👍

[@garytorresani8846]

Love hearing that sound. Like any hippie, I had a number of bugs and buses in the 70s.

[@carkingspot]

Great video. I would like to rebuild my 1600cc on my ‘71 SB for the first time. Never rebuilt any motor before.

[@DuRpTVproductions]

Super informative video and makes me super excited to eventually assemble mine!

[@jamesaucutt8284]

Nice job it’s always a satisfying feeling when all that work you do and it starts up on the first try that’s what you call a great accomplishment

[@icraftcrafts8685]

nice. when it started it gave me chills and goose bumps of joy

[@carolramsey6287]

What people don't get is that if you tune up for more power you get more heat. Big bore kits hot camshafts and twin carbs mean more heat output. Porsche got some of the heat away on the 911 by using sodium cored valves but even they had to go to water cooling eventually. Turn a 45 bhp motor onto 150 bhp and you got a lot more heat to get rid of.

[@ArneChristianRosenfeldt]

Did they talk about hot camshafts? 16% more displacement is like 16% more surface on piston and head. A little ceramic coating on head and piston for insulation. And on the valve face. Yeah, better go for more stroke, but engine bay is tight! I want extractor headers to extract the heat. Hi octane and compression reduces exhaust temperature and you don’t need sodium. Just don’t turbo

[@Colt45hatchback]

I cant recall the bore up size my dad went with in his hot rodded bug in the 70's his dad worked for deutz so he contacted a man in germany who got deutz parts imported to australia, and asked him to add the vw racing parts to the next crate of truck parts to come to the workshop, it was the largest set you could get for the block, which i believe was a 1200cc originally, apparently the case studs had to be slightly bowed to get it all together. Anyway the point i was trying to get at, was the kit came with different pulleys to turn the fan faster to prevent overheating

[@ArneChristianRosenfeldt]

@@Colt45hatchback I just want to believe that you can change the amount of heat going to exhaust vs going into cooling air can be increased by more RPM with faster combustion, shorter intakes. I think that racing engines play dirty, especially back in the day they did. Early exhaust valve open is good to get the heat out early, but may also be a sign that we need larger and more exhaust valves to center the exhaust pulse around BDC . Valve overlap at some point gives you inefficient idle and cruise: over heating. Last intake valve closing .. low torque at low rpm? So you need to rev the engine higher which gives friction? Higher pressure at high rpm which sends more heat into the walls.

[@dannyfoust3123]

My 64 and I enjoyed your video. Thanks!

[@TimsWorkshopTJY]

I have a 1200 40hp built in March of 1965 and it too had a hole blown but the #1 piston. I check everything else and the measurements are still good for new std rebuild kit. I found AApreformance has the 77mm kit for a pretty good price. Surprised I can still get a new kit for this engine.

[@richardsmith3350]

I was always taught to put the piston pin circlip with opening at top or bottom, never at side. At the side the clip is more likely to come out due to piston stop start forces.

[@cinemaipswich4636]

This motor is everywhere. It never dies. For generators, pumps, compressors, welders, beach buggies, sports cars, hovercraft...

[@pauljanssen7594]

One thing I always recommend for VW to aviation permatex to put the cases together to a bigger oil pump 3 Nordstrom the end of that crankshaft needed to be sanded smooth a lightened flywheel is a must it doesn't love the rear bearing to be pounded out little tricky to dry but it's worth the effort and gas mileage. And I always recommend the .009 distributor and if you're using oil bath air cleaner used dextran transmission fluid and filters a lot better you can feel it just a little bit more it just helps to lubricate the valves. I love building these engine it's good to have the rotating Mass balanced it's critical. One last thing run swivel feet on the rocker. Then you'll have a bulletproof engine.

[@julianroberts7116]

Great video mate, really nice with no talking all over it. One respectful word of advice though - PLEASE try to leave captions on for long enough for us to read them. There were a lot of graphics on here which disappeared off the screen before I was even half way through reading them. Apart from that - excellent, I loved it. Looks like you did a brilliant job.

[@pasanjayawardena7099]

Very clean job. They were assembled very carefully. Great work! 👍

[@shortchange26]

We had so much fun building these things. I could have one on the floor in 15 minutes.

[@Al-ce3xd]

Nice job! Btw a little trick with the cam plugs.. use a tiny bit of Locktight brand oil rated silicone.. just a small small wipe around the edge of the cam plug we’re it seats. They will usually leak without any silicone

[@arturomarquez4759]

Great video, especially looking at those master mechanic hands making precisely movements and handling large parts like a one of the best Mexican mechanic, perfectly job an video, especially those adjustments Mexican stile.

[@marcelo_rcosta]

Eu tenho um fusca 1964, 1200cc.👊 Você fazendo um motor é um artista. Meu sinceros parabéns! 👏🏻👏🏻👏🏻👏🏻

[@fletcher7149]

beautifully done mate

[@5speedMax]

Damn those Germans could engineer some practical, simple and elegant designed engines back 80 years or so ago.

[@gregfelice1969]

This was really well done. Thank you.

[@miguelvillanueva3498]

Gracias por un recuerdo de mi aventura por la vida soy eléctrico automotriz soy de Mexico cuando empecé a trabajar en este hermoso oficio fue con este maravilloso motor aquí en mi país fue el mejor auto en los años 80s te agradezco mucho tu video es excelente y gracias por recordar parte de mi vida

[@__-lb6sf]

VW Käfer! Und er läuft und läuft und läuft. Bei Min.1.09 ist ein Riss in der Zahnflanke der Nockenwelle zu sehen. Eine gute Gelegenheit, sie gegen eine geradverzahte zu tauschen.

[@davidgrisez]

My parents owned 2 Volkswagen Beetles. They owned a 1965 Volkswagen Beetle and a 1972 Volkswagen Beetle. These were the cars my father mostly drove and they were a favorite of my father. My mother did not like to drive these cars. She preferred the large Ford Station Wagons that had an automatic transmission.

[@blakjack3053]

That familiar sound is unmistakable

[@AffariSbullonati]

professional work, well cared for. Congratulations from our #affairsbullonati Team

[@tehnix89]

wow! this is wonderful!

[@jamesprice1253]

Nicely done.

[@brianspangenberg9598]

Had one in my so cal ‘61 ghia. The crank broke and I decided to upgrade to a 1835. This was back in 1986.

[@charlesevans9178]

PRETTY GOOD ENGINES THAT BEEN AROUND SINCE BEFORE WW2 $$$

[@flhusa1]

I had 2 40 horses .A 1960 and a 1963 . Good little engines back when speed limit was 55 . Now you would get run over by a distracted driver doing 80 !

[@albertogonzales3536]

El legendario motor boxer de VW la ingieneria alemana mas completa y practica de esa epoca. Mi padre era mecanico y los reparaba, ahora viendo este lindo video me hace recordar con nostalgia a mi padre empleando la misma tecnica pero con las herramientas de esa epoca el torquimetro no era digital.

[@simsneon2]

Nice video for someone who is mechanically inclined look for the le man they don’t have a clue what you’re doing an even me mechanic of 25 years I’m playing catch-up at the same time thank you for your video

[@vonhalberstadt3590]

Sweet. God bless Ferdinand Porsche, Rick Fayens and Carl Cordell. Orémus Y'all.

[@67VWForever]

Nice Video step by step I will put this video in my favorites and play this for my 67 bug Restoration 1500cc H motor I hope it's good it is frozen up but hopefully it's moisture rust seized and not low oil seized..

[@speed8701]

Notorious for blowing out spark plugs and stripping the head which was fixed with a helicoil insert.

[@michaelibey6700]

They only spit out sparkplugs if people screw up the threads. You need to remove the plugs when the motor is COOL and use anti-seize compound on them when installing.

[@brandons9138]

The OG tuner flat four. Suck it Subaru fans. These engines are like a Lego set for engine building. The swapping/mixing matching of different cranks/pistons to get the displacement you wanted to suit your needs. The variety of cams and carb setups alone is mind boggling. You could literally double the engine output easily. Plunk it all back into a car that at it's heaviest was what 1800 pounds?

[@heydonray]

GREAT VID. The best I’ve seen, and obviously a lot of care went into the making thereof. On a personal OCD level however, I cringed at the external appearance of the case and wished that it had been made as pristine there as on the inside. Just my personal hang up.

[@junkyard_kahrs]

Me too but it’s what decided to work with. This engine was outside in a field in Sacramento for 15+ years. I got it for free. That, plus keeping it mostly stock kept my costs down. There are so many perfect builds out there but a 40hp budget build is rare so I thought I’d try making one.

[@Hotrodman]

You remind me of the time when I restore 1200cc 40hp air cooled v4 of ZaZ-968m

[@edmundwessels2072]

We have to go back to the old technology, much better and everlasting.

[@stoveguy2133]

I had a 2180cc motor. Dual carbs. Pretty quick car

[@jimmynyoike]

That was satisfying to watch!

[@cristiantorelli4669]

Exelente video y mejor aún su trabajo 👌👌👌

[@LucasOliveira-dm8mb]

Incrível. Além de ter feito um serviço impecável ainda fez uma excelente filmagem parabéns

[@DianaLatexlover]

That´s the sound I love !

[@d-c-i]

Ottimo video! Nessun video tratta il montaggio del termostato..old bug never die...

[@charlesgraham9954]

my money pit was a 67 Bug, from 1990 to 98, ever extra dollar i made went into making that car quicker. 2 different trans and 3 different engine sizes. the city i grew up in Southern California, the south side of that city loved VWs. rags to micros, didn't matter, u seen Bugs everywhere there. i had a buddy with a 65, 1200cc

[@18Macallan]

Nice work gyus! 👍

[@samharris7911]

Great video...comments were often too quick though.

[@christiangarcia5606]

Sin duda los alemanes fueron unos genios al hacer esta obra de arte 😎

[@alexalanis4830]

Watching that was therapeutic.

[@deepaksolanki332]

Balance mind balance built. Good job. Thankyou ;for vdo

[@plainpaul]

Great video!

[@Pompomgrenade]

Great video!... Beautiful motor. I would throw that bad boy into a formulaV Car, to throw it between cones on an autocross course 👍

[@CableWrestler]

I watched it at half speed and the narration was still too fast 🙄 Having said that, what a wonderful video. I was glued from start to finish. Excellent workmanship.

[@lionsdejudah]

More like Art than a rebuild.

[@aSpyIntheHaus]

Quick question mate, sorry if someone has already asked this. But why have you settled 40 hp build. I mean I understand they're air cooled but is there other fundamental design constraints that limit the output of these engines. Like materials strength, composition, valve and port size etc.?

[@wallacegrommet9343]

Yes! All of those. This build is aimed at a little more hp/torque without sacrificing any reliability or longevity. These inexpensive, air-cooled engines were designed to be manufactured using readily available basic machine tools. The engine case is magnesium, usually, and has lightweight aluminum cylinder heads with pushrods. Powerful, inexpensive, reliable, lightweight…one of those has to go!

[@scallywagon9395]

Very nicely done video

[@Art-bq9zz]

Great show !!!!

[@clevelandrocksdzd]

Have you ever done a tear down rebuild on a swingarm transaxle? That would be awesome to watch

[@jonathasfigaro4992]

Last forever ❤

[@domingodeanda233]

That was pretty damn good, thanks

[@antoniomontana2232]

После такой красивой работы его будет жалко заводить !

[@albertogonzales3536]

Este vídeo me hace recordar mucho cuando mi papá reparaba estos motores legendarios VW. Un prodigio de la Ingeniería Alemana de aquella época, enfriamiento por aire bajo peso estable económico sinceramente muy bueno.

[@edwardchester1]

I'm all for the short and sharp approach to making videos but there's no need to rush this much. Just a little extra time to make the captions readable would've been good.

[@bedripolat1641]

Hep halini kurduğum işler.ellerinize saglik

[@YurtFerguson]

Was absolutely terrified for a second because when I first saw the naming of this video I thought it said 400 horsepower lol

[@michaelibey6700]

That's a rare late "D" model 1200 cc case, most 1200's didn't have cam bearing inserts or "O" ring seals on the 6 big crankcase bolts. People still look for those blocks I'm sure. I think most came in from Canada or Europe. I threw away many of the old-style blocks, nobody wanted them.

[@brianchisnell1548]

The reconditioned blocks have cam bearings and case savers.

[@홍콩대만다음한국]

이게 친환경이다 안전한 차이다 현대에 다시 생산되야할 차

[@Louisworldmyhobbysmylife]

Great video

[@OldCrowsClassicCars]

Awesome video. Could have painted that engine though

[@bearshield7138]

sweet job

[@keremardicli4013]

What a sound...

[@SlowSTEN]

The air-cooled VW motors are so cool, kind of a shame the only VW boxers still made are in Porsches (at least in the states)

[@calakask5485]

Wonderful

[@BACKWOODSLIFTER]

Well done