The engine. . .

So, the engine on this thing is basically all stock, 1600 dual port. The original VW engines don't have any oil filters on them and that simply will not do if I ever pan on taking this thing to the sand dunes. So I did what the VW enthusiasts call the "full flow oil bypass". This involves plugging the oil pump outlet and re-routing it through a external oil filter and back into the engine oil galleys.

I also had purchased a new weber 40 IDF carb. that I will be using for the turbo, but there is no reason can't through it on right now for fun (so I thought). I had to take the engine out to do all these things and when I did I found that one of the two engine/transmission mount bolts was cross threaded and only put in half way. >:( The more I get into this thing the more stuff I find. Here's are the things that I found during this step in the process:

1) Engine mount bolt cross threaded. - required 2 hours of careful blending work to clean up.
2) Drive axel bolts loose.
3) Rear trailing arm pivot bolt loose and about to fall out (bad news on the road)
4) Tail light wires are hard wired (I had to cut them to remove the engine cage)
5) All four spark plugs are different.
6) Fuel pump leaks fuel all over itself.
7) One of the bell housing bolts missing

I can't think of anything else right now, but here are some picks of all the work I did there:

Back Tires of and engine is out (this is were I started to find all this stuff)

New carb (weber 40 IDF)

Engine mount fixed and re-installed

Engine re-installed

Oil pump is coming out

Oil pump outlet is now tapped and plugged and ready to be put back in.

New external oil filter.

New oil pump cover that re-directs the oil to the filter.

All coming together.

Oil pump cap installed

I like it!

 

A video of the buggy running right after it all got put back together. The engine is much more responsive with the new carburetor.