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VW Air-Cooled Engines: How to Build Max-Performance
Of course, the enthusiast market did not see it that way. Aficionados loved the simplicity in the design as well as its aesthetics, and they enjoyed tinkering with the mechanicals of their Beetles, Buses, Type 3 models, and Karmann Ghias. There was (and still is) no shortage of options when customizing your Beetle, and for many, extracting as much performance out of the air-cooled flat-4 was the way to go. Not only does it remedy the issue of keeping up with modern traffic but Beetles also respond really well to modifications and have a robust aftermarket to support them.
In VW Air-Cooled Engines: How to Build Max Performance, VW veteran Dr. John F. Kershaw lays the groundwork for getting the most possible power for your desired use and application. Covered here are all the various power levels and components. This includes rotating assemblies, cylinder heads, the cams and valvetrain, engine blocks, ignitions systems, fuel injection, carburetors and induction, exhaust, sources for parts, and even turbos and superchargers.
Are you looking for just a little more power to keep up with traffic or maybe a streetable high-performance machine? Perhaps you are interested in a little street/strip action or even all-out racing applications. All of your options are examined in this book. Add it to your air-cooled library today.
Acknowledgments
Preface
About the Author
Chapter 1: Engine Design
Air-Cooled and Liquid-Cooled Engine Basics
Planning
Increasing Performance
Thermodynamics
Engine Combustion
Engine Fundamentals
Displacement
Performance Factors
Four-Stroke Cycle
Valve and Port Timing
Chapter 2: Horsepower and Torque
Engine Dynamometer
Calculating Torque and Horsepower
Compression Ratio
Fly Cutting the Combustion Chamber
Dynomation Simulation Software
Chapter 3: Rotating Assembly and Lubrication System Upgrades
Engine Core Selection
Stock Engine Setup
Cases
Lubrication System Modifications
Crankshaft and Connecting Rods
Flywheel
Chapter 4: Cylinder Heads and Camshafts
VW Head Castings
Valve Grind
Valvetrain
Rocker Geometry Setting Procedure
Porting
Chapter 5: Ignition System and Upgrades
Detonation
Preignition
Ignition System
Ignition Coils
Self-Induction
Mutual Induction
Creating 40,000 Volts Under the Hoo
Ignition System Selection
Advance Curves
Setting Ignition Timing on a Dynamometer
Coil
Electronic Ignition
Distributorless Ignition System
Magneto Ignition
Capacitive Discharge Ignition
Ignition Timing
Spark Plugs
Spark Plug Wires
Chapter 6: Powertrain Upgrades
Flywheel
Clutch Pressure Plate
Clutch Disc
Transaxle
Chapter 7: Induction System
Carburetion
Carburetor Modifications
Volkswagen Intake Manifold
Carburetor Make and Model
Carburetor Selection
Fuel Pumps
Electronic Fuel Injection
Forced Induction
Build Recommendations
Chapter 8: Exhaust System and Cooling System
4-into-1 Merged Exhaust Systems
Header Size
Mufflers
Heater Boxes
Open Exhaust Stingers
Building an Exhaust System
Engine Cooling
Chapter 9: Engine Builds
Common Rebuild Materials
Build 1: 1,600-cc Bolt-on Horsepower
Build 2: 1,776-cc Engine
Build 3: 2,110-cc Engine
Build 4: 2,165-cc Engine
Build 5: 400-bhp Engine
Source Guide
Of course, the enthusiast market did not see it that way. Aficionados loved the simplicity in the design as well as its aesthetics, and they enjoyed tinkering with the mechanicals of their Beetles, Buses, Type 3 models, and Karmann Ghias. There was (and still is) no shortage of options when customizing your Beetle, and for many, extracting as much performance out of the air-cooled flat-4 was the way to go. Not only does it remedy the issue of keeping up with modern traffic but Beetles also respond really well to modifications and have a robust aftermarket to support them.
In VW Air-Cooled Engines: How to Build Max Performance, VW veteran Dr. John F. Kershaw lays the groundwork for getting the most possible power for your desired use and application. Covered here are all the various power levels and components. This includes rotating assemblies, cylinder heads, the cams and valvetrain, engine blocks, ignitions systems, fuel injection, carburetors and induction, exhaust, sources for parts, and even turbos and superchargers.
Are you looking for just a little more power to keep up with traffic or maybe a streetable high-performance machine? Perhaps you are interested in a little street/strip action or even all-out racing applications. All of your options are examined in this book. Add it to your air-cooled library today.
Acknowledgments
Preface
About the Author
Chapter 1: Engine Design
Air-Cooled and Liquid-Cooled Engine Basics
Planning
Increasing Performance
Thermodynamics
Engine Combustion
Engine Fundamentals
Displacement
Performance Factors
Four-Stroke Cycle
Valve and Port Timing
Chapter 2: Horsepower and Torque
Engine Dynamometer
Calculating Torque and Horsepower
Compression Ratio
Fly Cutting the Combustion Chamber
Dynomation Simulation Software
Chapter 3: Rotating Assembly and Lubrication System Upgrades
Engine Core Selection
Stock Engine Setup
Cases
Lubrication System Modifications
Crankshaft and Connecting Rods
Flywheel
Chapter 4: Cylinder Heads and Camshafts
VW Head Castings
Valve Grind
Valvetrain
Rocker Geometry Setting Procedure
Porting
Chapter 5: Ignition System and Upgrades
Detonation
Preignition
Ignition System
Ignition Coils
Self-Induction
Mutual Induction
Creating 40,000 Volts Under the Hoo
Ignition System Selection
Advance Curves
Setting Ignition Timing on a Dynamometer
Coil
Electronic Ignition
Distributorless Ignition System
Magneto Ignition
Capacitive Discharge Ignition
Ignition Timing
Spark Plugs
Spark Plug Wires
Chapter 6: Powertrain Upgrades
Flywheel
Clutch Pressure Plate
Clutch Disc
Transaxle
Chapter 7: Induction System
Carburetion
Carburetor Modifications
Volkswagen Intake Manifold
Carburetor Make and Model
Carburetor Selection
Fuel Pumps
Electronic Fuel Injection
Forced Induction
Build Recommendations
Chapter 8: Exhaust System and Cooling System
4-into-1 Merged Exhaust Systems
Header Size
Mufflers
Heater Boxes
Open Exhaust Stingers
Building an Exhaust System
Engine Cooling
Chapter 9: Engine Builds
Common Rebuild Materials
Build 1: 1,600-cc Bolt-on Horsepower
Build 2: 1,776-cc Engine
Build 3: 2,110-cc Engine
Build 4: 2,165-cc Engine
Build 5: 400-bhp Engine
Source Guide
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