JBugs - Turn Key Assembly - Part 1 - VW Engine Tin Fitment

View our complete selection of air-cooled VW parts on the JBugs website: www.jbugs.com/
"Fit proper, then pretty!" - Sam Mebane - March 2024
OK, so it's been awhile since we've released anything on this "Unassembled" long block build. Almost immediately after this engine was finished, Sam got started on the 2234cc EMPI Engine Battle Build which was a whole fiasco from the hurried schedule, to the engine injecting a nut and punching a whole in a piston. Follow that with the tear down and the current rebuild....but we're getting away from the point of why we're here. We actually had the idea of doing an aftermarket engine tin video back in early 2020, but just never got around to it, until now! Well, then...but the footage has been sitting awaiting other projects.
So, here we are, or were anyway, beginning the completion of the EMPI Unassembled 1600cc Long Block Engine. Sam covers the process of test fitting all of the aftermarket engine tin, and the massaging (OK...hammering, cutting, grinding, trimming) that are needed to get the tin to fit tightly. A lot of additional work is needed on the fan shroud which is above what would be required on an original case since the "Unassembled" long block kit comes with an aluminum case which is thicker than the original magnesium unit.
Fan shroud aside, almost every piece of tin short of the doghouse exit tin will need some sort of work to get fit properly. The more original tin you have in place, the less work you'll have to do. Unfortunately, that is just the nature of aftermarket parts, there is a reason why most shops will pre-build their projects before body work, paint and final assembly. So this is why Sam installs all of the engine tin before mounting other engine components. Almost every piece of tin that gets installed, is pulled off for additional work. Often times, multiple times, and even once one piece is fit, more work will be needed once the next piece is installed.
By the end, Sam has most every piece (there are some pieces of tin that can't be bolted up to an engine on the stand) modified and fit, well. More importantly he covers the processes that will enable you to get your engine tin fit in place to your engine. Most importantly, is to get these steps done before your engine tin is painted, powder coated, chromed, etc. Get the tin fit properly first, then you can work on making it pretty! We can't tell you the number of comments we got when we first finished the assembly of the 1800cc stroker engine Sam built for his Super Beetle way back in 2019/2020. People were shocked and couldn't believe that we would fully assemble and run the engine with "unpainted" engine tin. That engine was later disassembled down to the long block and all of the engine tin was painted to match the car.
With all that being said, or typed....follow along, enjoy and see that aftermarket tin can fit well, just not as well as German, but it will do the job! Oh, and that fan shroud that Sam spent so much time fitting? It, the alternator, and fan are the same ones that got destroyed when the fan came apart at 7800 rpm on the dyno on the 2234cc EMPI Engine Battle Engine.
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Parts used in this video:
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Videos are intended for entertainment purposes. Factory specifications should be followed when performing any task on your vehicle.

[@akvistad6433]

👍Great that you make these errors for us. Most of us will most likely make these mistakes. Super that you show us how to solve it👏

[@RHicksjr777]

Thanks for making these videos. Helpful to novice's like me to see what to do when there are problems and what is proper installation.

[@pauljanssen7594]

One of my favorite things is assembly of motors , on the VW motors I would always put the baffles on the heads or I would forget them. I think the hardest part was dropping in that distributor gear and getting it lined up right.

[@ahernandez9860]

What a fight, at least you have the patience. Nothing like original fit tins. Guess were lucky china still makes these.

[@Sam_Mebane]

Something is better than nothing! Especially if it can be made to work.

[@ahernandez9860]

@Sam_Mebane Great Job!

[@clineadam9523]

First! Hope all is well 🙏 thanks for the video

[@Sam_Mebane]

We're still kicking!

[@vintage76vipergreenBeetle]

You forgot to modify the fan shroud, to clear the alternator tin exhaust at the bottom, just like the oem shrouds have.

[@OwhyeeVdub]

I was confused when I had to clearance an original just like my empi shroud.

[@vintage76vipergreenBeetle]

@@OwhyeeVdub Really. Usually, the original shrouds are good to go.

[@OwhyeeVdub]

@@vintage76vipergreenBeetle that's what I was told. But not me experiencing so far.

[@VWBaja]

For years it seems like all the after market tins have Very similar places they need to be clearanced. Why are the distributors of these parts not contacting the plants that stamp them to make improvements? I appreciate the video, but it seems like more effort could be put towards production improvements instead of how to modify inferior re-pops.

[@VWBaja]

Also, a bubble-top tin version would be helpful since a lot of people are choosing newer aluminum cases.

[@wastedwhiteboy2462]

Wow. Lots of fitment issues.

[@Sam_Mebane]

Par for the course with aftermarket tin. If it isn't German, fitting is required.

[@davidgiesfeldt6650]

I did this while the engine was IN the car… thanks

[@Sam_Mebane]

@@davidgiesfeldt6650 I’ve done it too…NOT fun!