Engine building

We have the experience and facilities to build all sizes of motor from a daily driven 1776cc to a monster 2443cc. All machine work is carried out by a local specialist precision engineer, we can machine cases for larger barrels and pistons, drill and tap for full flow oiling, and bore/fly-cut cylinder heads.

The first step in building an engine is to establish your budget and what you require depending on planned vehicle use - e.g. daily driver, weekend toy, or full-time race car.

The next step is to compile a list of engine components that will give the required performance, reliability and longevity.

We can supply you with a kit of all the parts you require after consultation for self assembly - although we would only advise this be undertaken by someone with experience of building VW engines.

If you are after a price then please contact us.

Engine assembly

All our engines - from mild to wild - are built the same way:

All components are throughly cleaned and inspected.
The rotating assembly (crank, flywheel, pulley, clutch pressure plate) are balanced using a constantly updated Hines balancing machine.
Components are dry-assembled to check clearances, tolerances and to calculate any required machining - e.g. barrel spacers, barrel heights, piston (deck) heights, cylinder head fly cutting, pushrod lengths.
After the machining has been done to obtain the required deck height, the pistons are balanced.
The barrels are honed to a finer finish to aid faster piston ring sealing and every piston ring gap is checked.
Connecting rod side clearances are checked.
Crankshaft runout is checked.
Camshaft end play is checked.
The camshaft is dialled in.
The valve train geometry is setup correctly.
Rocker shaft side clearances are set.
The engine components are cleaned once again and the engine is assembled.

Here are some pictures of a 2443cc engine during assembly:

Bench running

We offer a bench running facility. This enables the engine to be put through a rigourous pre-oiling routine to obtain oil pressure before the engine is fired and minimise initial wear between camshaft and lifters before start-up. The engine is then run for 30 minutes at between 2,500 and 3,000 RPM after which it is allowed to cool. The valve clearances are re-checked, the oil is changed and your choice of carburettors is fitted and tuned.