[Engine building]
[Engine fitting]
[Engine cooling]
[Exhaust systems]
[Beam narrowing]
[Out there now]
[In progress]
[News page]
[Contact us]
[Finding us]
[Bits & bobs]
[The JG54]


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:

Image 1 Image 2 Image 3 Image 4 Image 5
Image 6 Image 7 Image 8 Image 9 Image 10

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.

Image 1 Image 2 Image 3

© Copyright Funkenblitz 1998-2007