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Comments below. Keith Keith Park Top Notch Restorations topnotch@nycap.rr.com 71 Squareback 65 Notchback 65 Squareback 75 Opel 87 Golf 88 Rx7 10th Anniversary ----- Original Message ----- From: "Craig Webb" <craig_webb@ntlworld.com> To: <type3@vwtype3.org> Sent: Wednesday, September 03, 2003 9:43 AM Subject: [T3] Advice needed on building that 'Perfect' engine > My current engine (1584cc dual carb) in my '72 square is about done for and > a replacement will soon be needed. I'd like to take this chance to build > that special engine that will serve me for many years. Your ideas and > thoughts are welcome. > > What I want: > > Ultimate reliability, as good as you can possibly get for a VW engine. > Must run on normal unleaded gas. > Must be 'happy' around town and cruising for long periods on the highway. > (Max air temp here = 30 degrees C, say 100 degrees F) > Must be able to tow a trailer without overheating. I'll use it for daily > driving & holidays, fully loaded with kids, luggage and pulling a small > trailer. > Not after blistering acceleration or high top speed - 70mph fine. > Must be as fuel economic as possible > Would like to keep my standard dual carbs > Cost not a big issue, but not silly money MUST stay stock size... or you wont tow that trailer on the hot days for long. > > > My own thoughts so far: > > Biggest debate is to keep it stock size, or increase the capacity very > slightly. Don't mind machining the case and heads. I understand that 1776cc > is the max size recommended for a square due to cooling air restrictions - > correct? Actually knock 30% off engine life with 1776... BUT with a trailer, where your going to use that HP for an extended steady state time... youll have much less life than that. > > Ignoring the 'cc' size issue, thought I'd go with: > > Standard 1600 case, fully checked over, cleaned and align bored. Machine > case if needed, add case savers and drill for external oil filter. Id start with a quality NEW case for that warm N fuzzy... but if you know you have a case that isnt abused, ie. overheated or driven with loose bearings for long your OK with a line bore from a QUALIFIED shop. > > Go for a counterweighted crank, and pretty much standard everything else. > Get everything balanced as perfect as possible, including clutch plate. Any > thoughts on this - non standard cam perhaps?. Dont go nuts with the Cam... keep it stock or near. > > Standard heads, fully reconned. Best quality values & guides. Is it worth > a three angle value job and very mild porting and polishing. (basically just > cleaning up the combustion chamber)? Use only heads with VW cast in them. > > Keep compression ratio as stock or even slightly lower. Depends on what gas you want to use, but dont increase the compression ratio. > > External oil filter mounted from engine support bar. Any thoughts on either > remote oil cooler (with thermostat) or a deep sump? Can the standard oil > cooler be modified to a seven row one, similar to the bug upgrade? Go full flow but you dont need the extra cooler, you risk too low oil pressure when the engine gets older if you put too much in the oil circuit. 1.5 Qt sump to prevent starvation on corners but you gotta remember it hangs down under there if you backroading. > > Keep standard dual carbs (would these work ok with a 1776 with jet changes?) > Standard vacuum distributor with contactless points. Quality leads and high > power coil. Stock ignition is just fine, stock carbs will work with 1776 with a larger jet but I wouldnt reccomend the 1776. Of course for the ultimate in reliability and low maintenance go to stock FI :-) > > Other bits: > Lightened flywheel - worth it or waste of time? > Exhaust - standard or aftermarket? Want to keep my heaters. Lightened flywheel will make you keep stalling it with a trailer... not nearly as smooth drivability Stock exaust is best and quitest... get the later muffler with the larger outlet and single peice tailpipe. Quiet packs are OK but the quality is usually low and the break off in a year or so. > > > > That's my thoughts so far. If I go higher than 1584cc, am I going to > compromise my reliability? My current thinking is to keep it 1584cc, make > sure everything is a perfect as possible, nicely balanced, etc and > concentrate on maximising cooling and airflow. I see my biggest problem as > overheating when heavily loaded. Use QUALITY parts... OEM if possible... other listees can help with what they are and where to get them. > > Any help appreciated. > > Regards > > Craig Webb > 72' Square > UK. > > ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ > List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org > >