Cheap DIY Volkswagen Beetle Engine Run Stand - Engine Start Kit - and Simple Control Box Wiring

Walking through how to build and wire a Volkswagen Type 1 beetle bug start box so you can run your vw engine out of the car.
This DIY version can be done much cheaper than the Zalex Industries Engine Test Stand Control Box found for sale.
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VolkswagenPlanet / @volkswagenplanet
Busman 54 / @busman5429
Big W Adventures / @bigwadventures7061
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VW Nut 1967 / @vwnut1967
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[@chrisbegger8684]

You are the first person to explain this to me in a way that makes sense, thanks a bunch!

[@VWJawbreaker]

I appreciate the feedback and I’m glad the video was able to help you out!

[@peterlashua587]

Have tried bulbs good switch good power in the wires only thing I can think is speedometer needs very good ground so tomorrow going to ground to the battery directly if that doesn't work I don't know.

[@gutshotgriz3936]

For those running a stock carb, you’ll need to add a short jumper from the coil to the fuel shutoff solenoid on the side of the carb.

[@VWJawbreaker]

Indeed, thanks!

[@C10Trace]

Awesome, I set up mine up exactly like yours following your guidance, box, tach and wiring. It worked great…. 👍 perfectly! Thank so much!!

[@VWJawbreaker]

@@C10Trace glad the video helped ya out!

[@cubenitup]

Great! Personally I’d add a fuel pump switch to!

[@VWJawbreaker]

Thanks and not a bad idea 🤙

[@SpiralDesignWorks]

Gary was nice meeting you guys this weekend at bug jam. We need to get together since we are neighbors and all. Hopefully see you Sunday. -James

[@VWJawbreaker]

It was my pleasure !

[@mickperez1631]

I watch video closely and see the power from starter to alternator. This is the best how to out there. Thank you

[@VWJawbreaker]

It works great this way. You’re just using the starter positive post as a junction between the alternator and the battery.

[@gutshotgriz3936]

For those unable to find an old transmission housing to make your starter mount, a company called Zalex Industries makes a starter adapter ring for VWs…they’re a bit pricey at $140 or so, but they are well built. Depending on your starter model, you may need to provide the appropriate bronze starter bushing.

[@VWJawbreaker]

Correct and this was in response to people who wanted a diy approach.

[@TheWhitetailrancher]

Gary, I've always enjoyed your channel. Hope you know that! Right now I'm quite concerned how you are doing in the weather situation. I'm praying for you buddy!

[@VWJawbreaker]

I really appreciate that buddy. We faired really well considering how bad others did. We’re very fortunate and blessed overall.

[@michaelknight2897]

I'm totally doing this. Reversing the order of buttons though.

[@VWJawbreaker]

Of course, make it work for you!

[@damonroundtree5339]

Thanks for keeping it simple. Always enjoy checking out your videos.

[@VWJawbreaker]

I appreciate you being here!

[@mondospeedy3089]

Very nice, this is something you could sell.

[@VWJawbreaker]

Thank you but it’s more satisfying helping others build their own.

[@VwRosstorations]

I started on one of these years ago...never finished it..I’ll revisit it when it comes to engine time. (No time soon 😂) 👍🏴󠁧󠁢󠁥󠁮󠁧󠁿

[@VWJawbreaker]

Hopefully it’ll help you finish up your box!

[@mcdanielsmotorwerks423]

Thank you for producing another quality informative video. Keep sharing your wisdom and the world will become a more informed place to be!

[@VWJawbreaker]

As long as I continue to gain my wisdom form you I’ll be just fine!

[@mcdanielsmotorwerks423]

@@VWJawbreaker like I always say just because I give advice doesn’t mean I know more, it just means I’ve made more costly mistakes.

[@VWJawbreaker]

@@mcdanielsmotorwerks423 true.... but together we are more knowledgeable.

[@mcdanielsmotorwerks423]

@@VWJawbreaker TRUTH!

[@GoodOldMike]

perfect timing ! I'm about to go out and re-hook up mine as it got disconnected (torn up) when it was moved around during my hiatus. Nice clean setup. Jawbreaker Certified!

[@VWJawbreaker]

Man I wish we were closer, I’d come up there and lend a hand for a weekend!

[@KSFWG]

Now I know your secret to keeping all your tools clean! You have a dedicated washer/dryer for them! How cool is that !!?? Waaay Cool ! ;) lol

[@VWJawbreaker]

Hey, you weren’t suppose to figure that out! 😂😂

[@KSFWG]

I'm just a tad bit smarter than I look... :)

[@VWJawbreaker]

@@KSFWG 😂 lol

[@vwmountainman9701]

Really like the channel. Interesting to see the difference & similarity of engine builders in the VW arena. Just moved from NE Kansas to northern Arkansas. Once I get my shop all set up - I need to raise my engine mount on my run stand.. Nice video - keep em up !!!

[@VWJawbreaker]

I appreciate you being here and for the kind words. We all learn differently and we all have different ways of doing things… I’m tossing my stuff out here and there so many great comments from many others…. We all learn together and we’re better together.

[@martinharris5017]

Nice work! A handy setup. Thanks for the easy to understand explanation.

[@VWJawbreaker]

Thank you for taking the time to comment. I’m glad you found the info useful! Thanks for being here, have a great rest of the week.

[@GarageMisadventures]

Nice. I may have to revisit this soon. I’m getting stuff together to start on building an engine for the first time.

[@VWJawbreaker]

That will be cool, hope you plan on videoing it!

[@GarageMisadventures]

@@VWJawbreaker thanks Gary. Yeah it will be my first engine build that isn’t for an airplane ha. So I’m sure I’ll have some video of it. It will be for a new project we just picked up.

[@VWJawbreaker]

@@GarageMisadventures definitely try to film some of it, I’d like to see what you’ve been up to.

[@conrad1468]

Great job!!

[@VWJawbreaker]

Thank you sir.

[@HHWheels]

If I didn't already have a hook up for one, this is definitely what i would build. great video!

[@VWJawbreaker]

Hey thanks!!

[@HapticGarage]

Great rendition of a test stand start box. The shop built tools are the most fun!

[@VWJawbreaker]

You are 100% correct good sir.

[@2GuysandaBug]

I remember watching your video on cutting the bell housing. Like the setup. Simple put very functional.

[@VWJawbreaker]

It is very simple and costs so much less than a store bought setup.

[@dubworldvwadventures]

Thanks for sharing Gary. I need to build one of those!

[@VWJawbreaker]

You’re more than welcome, hope it helps you along.

[@williamtanner1372]

Very well explained. I'll make one when I get a chunk of bellhousing. Thanks for the video!

[@VWJawbreaker]

Glad you enjoyed it. Hope it helps you down the road.

[@NortheastVintage]

Great information. Thanks for sharing.

[@VWJawbreaker]

Hope you found some little things helpful 🤙

[@ChipsAndSparksGarage]

A very professional setup! I still need to trim my bell housing, so I can run on the stand, instead of the floor.👍

[@VWJawbreaker]

Yes sir, that was the biggest reason I trimmed the bell housing the way that I did.... it fits on my engine stand!

[@KCPurpleBug]

Thanks for the video after I watched your video I changed mine, it worked but I liked the way yours looked

[@VWJawbreaker]

Awesome man, glad it helped you out!

[@SladesVWBeetle]

Very informative video and explained well! Thanks brother!

[@VWJawbreaker]

So many have asked, figured I’d better do one sooner or later!

[@SladesVWBeetle]

@@VWJawbreaker Absolutely!! Very good video!

[@christopherthrasosmedia2698]

Awesome man!!! Cheers from Vegas!

[@VWJawbreaker]

Thank ya sir! Cheers and have a great day.

[@christopherthrasosmedia2698]

@@VWJawbreaker On a seperate note, the dual 34 picts you're running, I bought the kit. Does the stock fuel pump sufficiently supply fuel requirements for these as duals?

[@VWJawbreaker]

Yes sir it sure does. Just verify your fuel pressure as I’ve seen stock pumps put out way too much pressure. If the pressure is high, just add in a pressure regulator

[@richpeacock5768]

Very nice setup! if I were to build one, I would copy yours cuz it would be much nicer than the one I would come up with. Have a great day Gary.

[@VWJawbreaker]

Thanks buddy! Hope you’re having a great week!

[@busman5429]

Gray if I did not have all mu health problems I would do a set-up like you built. Nice neat clean box.

[@VWJawbreaker]

Thanks buddy, the one you did is really nice as well! I love your setup but I needed one more portable.

[@backyardkombi5466]

Really useful video

[@VWJawbreaker]

Why thank you!

[@user-fy5qj7vf7r]

I was just curious if you can post what brand that box is. I have all of the parts thanks to your awesome video, interested in the box itself. Thank you for your time!

[@VWJawbreaker]

Not sure of the brand but is an 8x8” electrical box from the home improvement store.

[@cwkhonda]

back in the day I cut up an old trans housing, and everything else on a pallet.. worked great.. that engine stand and adapter seem a bit marginal.. I was about to buy the adapter you have, but now cad drawing my own version and weld one up.

[@VWJawbreaker]

That’s what I’m using is a cut up bell housing from a type 1 transmission. The stand is super solid, the yoke could use some reinforcement but I haven’t had an issue at all over the last several years.

[@cwkhonda]

@@VWJawbreaker yep, but your bell housing hack is much cleaner than what I made.. I was 16 so 35 years ago... I'm headed to the shop now to cnc plasma cut my parts for my stand adapter now.. I'll post a pic if it works...lol

[@VWJawbreaker]

@@cwkhonda amazing how as we get older we do things nicer lol Definitely keep me posted, I’d love to see it.

[@cwkhonda]

@@VWJawbreaker so I made my mount. I think it turned out pretty good aside from the 2.375 pipe I acquired, ended up being hot dipped galvanized, but I didn't want to wait for material. I guess I can't post pics here.

[@VWJawbreaker]

@@cwkhonda I’m sure it turned out good. Shoot me an email with pics At [e-mail]

[@superochosvwcorner4782]

I’m going to try to make that

[@VWJawbreaker]

It’s easy enough honestly.

[@unclea1bert]

I need to make one

[@VWJawbreaker]

Hopefully the video will help you get one built.

[@jcnavas86]

Great video. Probably you shall build and sell that box...

[@VWJawbreaker]

I’ve gotten a few requests but I don’t see it being cost effective.

[@borna430]

Thanks for this great info. I am building one similar to yours. I see that you connected the negative (black alligator clamp) to the starter housing. Where did you connect the other end if it?

[@VWJawbreaker]

No problem, hope you enjoyed it! The other end of the negative is connected inside the box for the tach

[@mickperez1631]

Great stuff! My only question is the alternator . Do you have power going to B+ from battery and when the alternator light is off it means it is working or charging?

[@VWJawbreaker]

Answers in the other comment.

[@underlook8867]

Great video! Is there ever a concern that the engine case could break at the two attachment points to the engine stand due to the added stress of running the engine. That setup is so convenient, but I would cry if my old engine case broke and the whole engine fell on the floor!

[@VWJawbreaker]

Glad you enjoyed the video and thanks for letting me know! No worries on running the engine on the stand, many have ran like that over the years without issue at all. I’d worry more about the strength of the stand more than the attachment points on the case.

[@jwhrivnak]

Great video. What size fuse did you use?

[@VWJawbreaker]

Great question! I want to say it was a 20a fuse which is overkill but sized for the main wire I’m using.

[@johannsmit2001]

Sir thanks for your greatest invention since sliced bread. 2 questions. 1. Do you have to cut the bellhouseing? 2 . This system charges the battery while operating? Thanks again . Johann - South Africa Cape Town

[@VWJawbreaker]

Haha, I appreciate that but I’m jt the only one who’s come up with this setup. It’s just the way I made it work for me. Yes, I cut a type 1 gearbox bellhousing off and used that to hood the starter. Yes, this setup also charges the battery when running. You just need a wire from the alternator to the starter positive post where you hook the positive battery cable to.

[@johannsmit2001]

Sir thanks for your reply. So in the perfect world I can start and drive my dune buggie. Minus all the lights and other electrical equipment.

[@VWJawbreaker]

Absolutely you can! I used it before in a Manx clone to move it around for a friend. Definitely multipurpose.

[@johannsmit2001]

Sir I will keep you updated . Thank you so so much. You know probably better than anyone. This flat fore movement has away to get under your skin . You end up living the experience everyday. You know what I mean.

[@vintage76vipergreenBeetle]

Going to build one.👍

[@VWJawbreaker]

Lemme know if you have any questions, but the video should cover most everything.

[@vintage76vipergreenBeetle]

@@VWJawbreaker Will do.👍

[@VWJawbreaker]

@@vintage76vipergreenBeetle have a great rest of the week ✌️

[@vintage76vipergreenBeetle]

I just finished the start box. 🙂 I haven't tested it yet. Maybe in the coming months, l'll record a short video of box in service.

[@VWJawbreaker]

@@vintage76vipergreenBeetle please do, I’d love to see it!!

[@AntonioMartinez-iv3iq]

Hi,nice vídeo building a sandrail i like your vídeo but do yo have any plans For fuse box to use 6 fuses, thanks from mexico

[@VWJawbreaker]

That’s the only video that I currently have for wiring.

[@donaldpelletier6654]

Great video. What battery do you use or recommend for a High Performance high compression stroker engine (Type 1)? Thanks

[@VWJawbreaker]

I’ve been using the optima red top with great results.

[@borna430]

Great Video. Where can I get control box?

[@VWJawbreaker]

You can get just the bud at most home improvement stores or electrical supply store.

[@MP-hx8fs]

Nice videos. Do you know where to get the butterfly valve that goes in the heater channel under the back seat that is controlled buy the cable on a 69. I have checked my junkyard and they don’t have it.

[@VWJawbreaker]

Thank you for being here and watching. Not sure where to get that heat duct valve, I’ll ask around and comment back if I can find one. Not a lot of people I hang out with run heat.

[@VWBEETLEOVAL1955]

a good setup to start a engine. but where did you get the rpm signal? from a sensor at the flywheel?

[@VWJawbreaker]

Rpm signal for the tach comes from the negative side of the coil.

[@michaelknight2897]

Is there any value in adding a volt and oil pressure gauge? What amp rating are you buttons and switch?

[@VWJawbreaker]

There value on adding those of you want to add them. I usually run a manual oil pressure gauge and put it in the oil sender spot for running on the stand. Switches are all rated for 10a and the starter button is either 30 or 40a.

[@caseythompson2347]

Will led lights work for indicators? Some one told me they won’t draw enough to work correctly?

[@VWJawbreaker]

Led will work fine for oil light hit you’ll need an incandescent for the alternator.

[@borna430]

Hello, Few more technical question. What is the rating as far as amp on the inline fuse and switches?

[@VWJawbreaker]

I don’t recall the fuse size but I think it was a 20a. The switches are rated for 10a each except for the starter one which is designed to be used for a starter.

[@The_Devil_Nside]

Killer vijeo.

[@VWJawbreaker]

Thank you 🙏

[@knockout818]

Good video but, what if it’s a generator ?

[@VWJawbreaker]

Then you’ll need more wire and a voltage regulator.

[@lordsauto]

Can u use this for any engine GM?

[@VWJawbreaker]

I don’t see why not. May need to modify the wiring to suit your needs.

[@user-hy1jz1fn4s]

With the start and on off switches, do I have to wire them up as well and does that wire go to ground?

[@VWJawbreaker]

@@user-hy1jz1fn4s the start and off switches interrupt power, do not wire those to ground.

[@user-hy1jz1fn4s]

@@VWJawbreaker thanks

[@chiphewlett6144]

There are five ternimals on my coil. Which one gets the red wire? I have a generator. Which terminal does the ivory colored wire go to? Where do the opposite ends of the alligator clips go? Where do the other ends of the red, ivory, brown and green wires go? Sorry for the ignorance., I'm not attaching a tack. Where did you get the red and greed lights for the alt and oil?

[@VWJawbreaker]

There are only 2 posts on your coil, a + side and a - side. Power goes to the + side. If you have a generator you’ll also need to wire in a voltage regulator. The answered to your other questions are in the wiring diagram. Red and green lights came from a surplus store near by. You could also get them from Amazon or eBay.

[@chiphewlett6144]

@@VWJawbreaker There are 6 spade terminals on my Bosch coil. Three for neg. and three for pos. I had to remove the coil to determine which side was +. thanks mucho for your help!

[@VWJawbreaker]

@@chiphewlett6144 glad you got it sorted out 🤙

[@KCPurpleBug]

Gary I'm having trouble with my starter box I think it may be the old starter and solenoid, it has a lug up on top and it goes to the starter and the other one goes in under the solenoid and it has two plugs 1 is horizontal and it is one top and the other one is vertical and on the right side of the end of solenoid. and when I hook it up like yours the starter starts running

[@VWJawbreaker]

Did you try the other lug? Does the solenoid wire coming off of the button have constant power for some reason?

[@KCPurpleBug]

@@VWJawbreaker It could have I need to check it out, way to cold to spend much time in the garage been in the cold -9 up to 19

[@VWJawbreaker]

@@KCPurpleBug it’ll still be there when it warms up. Stay warm and safe!

[@KCPurpleBug]

@@VWJawbreaker Yes it seams to, I will try it when I get my empty trans case back and try it, My box is just like yours other than I bought a 8x8 box and thanks for your help

[@VWJawbreaker]

@@KCPurpleBug happy to help, hope you get it sorted out once things thaw a bit.

[@VolksStokes]

Love it! By any chance could you sell me your Ready-Made Bellhousing unit? 😬🙄 Otherwise I have to buy more tools to customize that and im out of $pace here 🥺

[@VWJawbreaker]

Unfortunately I use it too often to be able to part with it.

[@VolksStokes]

@@VWJawbreaker Gotcha! Now I need to wash more dishes to please my wife so I can buy more tools and parts 🥶😭😂

[@VWJawbreaker]

@@VolksStokes that’s usually what happens around here also! Happy wife, happy life!

[@markgregory2355]

Have you a more detailed printable wiring diagram?

[@VWJawbreaker]

@@markgregory2355 sorry, I do not.

[@user-hy1jz1fn4s]

As I’m a bit of a dummy with auto wiring I was trying to work out the wiring by taking screenshots of your video. I’m trying to work out your whiteboard diagram slowly

[@VWJawbreaker]

@@user-hy1jz1fn4s I understand. That white board diagram got wiped away 3 years ago… wish I had something to send you.

[@user-hy1jz1fn4s]

Hi Gary, with the active wire to the start switch, does it connect to off side or the on side of the master switch? Thanks.

[@VWJawbreaker]

@@user-hy1jz1fn4s I wired everything off of the master switch.

[@user-hy1jz1fn4s]

@@VWJawbreaker on your diagram it looks like the power wire is going to the OFF position on the master switch

[@VWJawbreaker]

@@user-hy1jz1fn4s well, you’re asking about a diagram I drew 3 years ago lol It would need to be wired to the ON side of the switch that way the master switch would kill everything. Unless you want to engage the starter with the master switch off.

[@user-hy1jz1fn4s]

@@VWJawbreaker I’ve set up my start box the same as your box. So then is there any wiring required to come off the OFF position on the switches. Incidentally do you still use the box you built 3 years ago?

[@VWJawbreaker]

@@user-hy1jz1fn4s yep, still use the same box and it’s been working great for my needs. Your incoming power goes to one terminal of the master switch. Everything else comes off of the other terminal on the master switch so the master switch kills everything. I just looked at the video, on the bottom of the master switch is a fused 12v input. Everything else comes off of the other post on the switch.

[@user-qc2le3wm7j]

Do you make the box for sale

[@VWJawbreaker]

No I don’t.

[@joshgreenwood2412]

Wondering what switches to use? Does it matter?

[@VWJawbreaker]

It really doesn’t matter, other than the starter push button they don’t have any real amperage going through them.

[@joshgreenwood2412]

@@VWJawbreaker should that one be 12v

[@VWJawbreaker]

@@joshgreenwood2412 they should all be 12v rated.

[@cdub10090]

Stupid question, where did you get the wiring?

[@VWJawbreaker]

Leftover from this and that….

[@user-qc2le3wm7j]

Do u sell the box

[@VWJawbreaker]

I do not.

[@dhmmus8641]

1:48 hervorragend

[@jorgeschmidt]

You missed showing the tachometer connection

[@VWJawbreaker]

Tachometer hooks to the negative side of the coil.

[@dr.jorgeschmidt8023]

from the tachometer switch I see a connection that connects 2 cables, one red and one white, where does it connect? It gives the impression to the tachometer but in my tachometer it has 3 wires, red, blue and black (ground). should i connect the blue and red to the tachometer swith?

[@VWJawbreaker]

@@dr.jorgeschmidt8023 not sure what brand tach you’re using, different manufacturers wore them different. Normally, one wire will be ground, one will be ignition switch positive and one goes to the negative side of the coil. Others also add in a wire to hook up for backlit illumination.

[@peterlashua587]

I live near ocala having problems with wiring on my superbeetle need help .

[@VWJawbreaker]

What type of help are you looking for? Some advise or someone to work on it?

[@peterlashua587]

​@@VWJawbreakerspeedometer ligts won't work

[@VWJawbreaker]

@@peterlashua587 check to see if you have power to the lights on the speedo. If so, bad bulbs. If not, probably headlight switch.

[@peterlashua587]

​@VWJawbreaker no need someone advice about the problem is it the ground.

[@VWJawbreaker]

Could be power, could be ground, could be the bulbs.

[@mohdrhaiz8146]

No starter relay required?

[@VWJawbreaker]

Nope, the push button switch is rated for the load.... it’s actually a push start universal switch.

[@mohdrhaiz8146]

@@VWJawbreaker thanks for sharing!

[@VWJawbreaker]

@@mohdrhaiz8146 thank you for watching!

[@mary8273]

What was your cost??

[@VWJawbreaker]

I had the wiring, old worn out transmission case.... I think I might have $30-40 total into it.

[@VWRICH23]

Now hows all that done again????... 😜 Jk

[@VWJawbreaker]

Back to green and hold your left arm over there. 😂