Getting Started
The first thing I did was to make two lists:
1. a wish list of everything I wanted for a dream engine
2. a list of everything I needed so that
I could have an engine for next years season, even if our budget was really limitedI took these lists, created an estimated budget, discussed things with my
wife, this is a necessary step if you want to remain happily married, and came up with a
compromise engine between the two lists. In my situation, my budget was initially
set at a total of $2000.00 for the whole engine rebuild. One point worth noting, in
projects like these, always expect that the actual money you spend will exceed your
estimate by at least half again as much as your estimate. This is exactly what
happened to me. When I'm done I'll have almost $5000.00 into the whole project, $3500.00 for the engine alone.
Mail Order vs. buying locally?
This is a decision that all VW owners face. My motto
is this, if you are only saving a few dollars once you add shipping to the mail order
price, it is well worth those dollars to buy locally to avoid a long distance relationship
if any of the parts are defective or mis-ordered. I have noted which parts are mail order
and which were purchased locally, and you will notice that I grouped orders so that if I
had to pay shipping, is was for more than one or two things.
If you want to learn more about the people that you are
ordering parts from, go to my Rating VW Mail Order
Companies page.
List of
Parts
|
Notes:
The following tables list all of the parts that I ordered for the engine
build. This lists includes items that I totally didn't account for when I did my
initial estimate. |
| This list might
be able to help someone else come up with a more accurate estimate for their engine build.
The thing to remember though, is that even though the total here may look expensive, and
you can probably come up with other estimates that look better/cheaper on paper, if you
aren't cutting corners and you want the best use of your money, you will end up spending
about this much for a comparable engine. One last note, my application is for a sandrail, not a street car. So,
this list may help people choose some parts over others for a street car, but it won't be
the best choice for ALL parts for a street car. For example: Iin my situation I
don't have to consider some of the problems associated with running 10:1 compression,
cooling isn't an issue in a sandrail like it is in a street machine, and longevity isn't
either. |
Engine Hard Parts
| Part |
Description |
Comments |
Price |
| Engine Case |
CB Performance
Super Case, clearanced for 82mm stroke, 94mm pistons/cylinders |
Best
price/quality without puchasing an aftermarket case |
$489.95 |
| Connecting Rods |
CB Performance
Super Race Rods, 5.6 inches, Chromoly |
These rods are
available everywhere for about $270 to $300, so i just decided to get them at CB Perf.
since I was buying my heads and case there |
$279..95 |
| Cylinder Heads |
044 Magnums
machined for dual valve springs |
These are the
best heads available for the money, IMHO |
$189.95 ea. |
| Pistons &
Cylinders |
94mm X 82mm
Mahle graphite coated pistons & cylinders |
Best for the
money. I wouldn't recommend 94s for a street car, but they are great for a Sandrail |
$169.50 |
| Crankshaft |
82mm
Counterweighted crankshaft |
Seemed to be the
best priced/quality from recommendations, but I was unpleased that the crank wasn't
polished, and I couldn't get my core charge back unless I had a good std/std crank for
exchange. Next time I will go to Scat |
$334.95 |
| Oil Pump |
Melling High
Volume Oil Pump |
Most used pump |
$45.00 |
| Head Studs |
8mm Chromoly
studs |
Reduces the
chances of having to retourque the heads, allows you to be able to tighten the heads
slightly more, they don't stretch like stock studs |
$64.95 |
| Pushrods |
3/8"
Chromoly Pushrods |
Allow you to run
.000" valve lash, don't flex like stock pushrods, create much more valve train noise |
$39.00 |
| Valve adjusters |
Swivel feet
valve adjusters |
Excellent choice
for reducing valve guide wear, as well as improving valve lash adjustability |
$19.95 |
| Drive Gears |
Straight cut,
steel cam and crank gears |
Reduces cam
bearing thrust wear, sounds cool :) I don't know if I would recommend this for
street use, it depends on whether the gear noise is annoying to the owner |
$99.00 |
| Main Bearings |
.010 over Main
bearings |
|
$24.00 |
| Rod Bearings |
Std. rod
bearings |
|
$10.00 |
| Cam Bearings |
Double thrust
cam bearings |
|
$10.00 |
| Total Seal
Piston rings |
2nd Ring only |
These are the
best thing to get to ensure that you don't have any comression or oil vapors leak by your
piston rings. |
$69.00 |
| Lifters |
Lightened
lifters with smaller pads for clearance of high-lift cams |
These are great
to reduce reciprocating mass in the valvetrain. They also reduce the chance of
having to clearance the lifter bores for your high-lift cam. |
$48.00 |
| Gaskets |
Full Gasket set,
Red rear main seal, xtra oil cooler seals |
All gaskets
needed for an overhaul |
$12.80 |
| Solid rocker
Shafts |
Buckpack solid
rocker shafts |
These elliminate
the wave springs that are used on a stock engine and can break apart, at high rpm, and end
up in your oil. |
$42.00 |
| Cylinder Spacers |
These add deck
height to the cylinders to allow for different compression ratios |
RIMCO is the
only company that I have found that makes these, and they do excellent work. |
$50.00 |
| Oil cooler |
New Doghouse oil
cooler |
This was
required since the previous owner mounted his to the back of the fan shroud, and didn't
use any other oil cooler |
$57.00 |
| Oil Cooler
Adapter |
Doghouse oil
cooler adapter |
Required to use
the Doghouse oil cooler |
$15.99 |
| Clutch Disc |
4 puck sprung
clutch disc |
|
$89.00 |
| Pressure Plate |
Kennedy 2100 lb
pressure plate |
|
$109.00 |
| Shipping &
Handling |
Total shipping
and handling cost from all parts I ordered through the mail |
|
$51.00 |
TOTAL COST |
$2509.94 |
Top
External/Dressup Parts
| Part |
Description |
Comments |
Price |
| Electronic
Ignition Module |
Compu-Fire
module |
|
$69.00 |
| Hoses |
Fuel hose and
breather hose |
|
$27.40 |
| Cylinder tin |
Chrome cylinder
tin |
I needed this
since the old tin was some handmade job from alluminum |
$29.95 |
| Fan shroud |
Chrome doghouse
w/o heaters |
|
$69.00 |
| Alternator kit |
Std. 12V
alternator kit |
|
$129.00 |
| Air cleaners |
6" tall
oval air cleaners |
The old air
cleaners were rectangular, thrashed, and their base plates wouln't allow for velocity
stacks |
$68.00 |
| Velocity stacks |
Weber 44 IDF
velocity stacks |
The carburetors
I had didn't have any velocity stacks |
$60.00 |
| Crank Pulley |
Empi Laser
etched degree pulley w/sand seal |
This is the best
non-dampening pulley on the market. It's degree marks won't come off with carb
cleaner, and it looks great. |
$55.00 |
| Chrome Cool Tin |
Designed to
replace the standard small pieces of tin placed under each set of cylinders |
These were
originally designed for Type 3's, but work great on all Type 1, 2, and 3 engines |
$15.95 |
| SuperTrapp
Muffler |
Stainless Steel
muffler |
The best muffler
you can buy for offroading/sandrailing |
$122.54 |
| Chrome Coil
Bracket |
Coil Bracket |
|
$4.79 |
| Chrome
Alternator Nut |
Alternator nut |
I normally
wouldn't have bought this, but the generator nut I had was the wrong thread, and I didn't
want to buger the alternator shaft |
$5.95 |
| 1-5/8"
Tri-mill bobcat merged exhaust with U-bend pipe |
Chrome |
This is the best
size for the 2275cc engine and Tri-mill is well known for their quality exhaust systems
for sandrailing/off-road |
$130.00 |
| High Pressure Remote Oil Hoses and fittings |
Stainless Steel
high pressure hoses and AN fittings |
These are
aircraft quality hoses and fittings that will be perfect for standing up to the
environmental effects of sandrailing |
$110.63 |
| Chrome Coil |
Perlux Flame
Thrower 40,000 Volt |
This coil
matches the PerLux ignitor, and will make for a great combo for the ignition system |
$37.00 |
| Seats and
Coivers |
Poly high-back
bucket seats with vinyl covers |
|
$197.00 |
TOTAL COST |
$1425.12 |
Top
Miscellaneous Parts
| Part |
Description |
Reason for Choice/Options |
Price |
| Engine Case
hardware kit |
Oil pressure
relief pistons, springs and caps. Engine studs, etc. |
This is an
excellent kit to buy instead of getting the aftermarket high pressure oil kit. The
aftermarket kits are cheap and the springs have a tendency of breaking, and they don't
include the plugs to hold them into the case. |
$13.00 |
| Intake Manifold
Gaskets |
Extra Thick
gaskets for use with Weber Carbs |
|
$1.99 |
| Weber Carburetor
Rebuild Kits |
These kits are
used to replace all soft parts within the Weber carburetors, as well as the needle and
seat and accelerator pumps |
Two of these
kits are required to rebuild a set of Webers, the following price is for both kits |
$52.00 |
| Weber Carburetor
Base gaskets |
These seal the
bases to the manifolds |
The ones that
came with the rebuild kits were pretty cheesy |
$3.96 |
| Ignition Wires |
Std. German
Ignition wires |
|
$12.95 |
| Wave Washers,
Assembly Lube |
Assembly lube is
for making sure everything has lubrication when initially installed/assembled |
The wave washers
didn't come with the case nut kit, so I had to buy them separately. The through
bolts, about 4 or 5 of them, didn't come with the case locknut set either. |
$9.50 |
| Permatex 2H |
|
This is used to
seal the case halves together, a definite must! |
$3.79 |
| Grease |
Molybdenum
grease |
This is used to
lubricate the bearings, lifters, cam, and oil pump during assembly. Hence it's
alias, Assembly Lube. |
$2.02 |
| Pushrod Tubes |
Windage tube
pushrod tubes |
These extend
further into case to reduce the amount of oil that poors into the valve cover, thus
keeping more oil around the parts that need it. |
$23.95 |
| Spark Plugs |
NGK 3/4"
reach plugs |
Coming soon |
$6.00 |
| Lochtite |
Red Lochtite |
This is a
requirement for virtually every bolt on the engine, especially the camshaft to gear bolts,
rod bolts, and case halves studs/nuts |
$5.00 |
| Case nuts |
Lock nut engine
kit with all nuts required to bolt an engine together |
This is a
requirement along with the previously mentioned locktiting. This will help to
ensure that your engine will not leak |
$3.98 |
TOTAL COST |
$138.14 |
Top
Suspension Parts
| Part |
Description |
Reason
for Choice/Options |
Price |
| Rear Struts |
KYB Struts |
|
$133.00 |
| Front Shocks |
KYB Gas shocks |
|
$38.00 |
TOTAL COST |
$171.00 |
Parts Still to buy
| Part |
Description |
Reason
for Choice/Options |
Price |
| 2"
Lap/shoulder harnesses |
Seat Belts |
These will
replace the lap only belts that I currently have for the small jump seat that the children
sit in |
$90.00 |
TOTAL COST |
$90.00 |
Top
The Grand Total Price
Top |
