Can't say enough about all the great work Bruce did getting the engine together. Starting with the aluminum case he recommended that we sourced through Bill, the build was a great lesson. I'd never try to build an engine by myself. I'm aware enough to know I don't have the time, patience. expertise or cleanliness in the garage setting to put one together to know it would be done right. To say I'm thrilled with what Bruce put together would be a major understatement. He did a fantastic job. It runs like a top with plenty of power.
There's so much little stuff that Bruce did that makes such a difference to a great running functioning bus. It's too much to list and go through, but it makes all the difference in the world. Little stuff. He spent hours tweaking and fixing stuff I would have struggled with for years.
In addition to the aluminum block, I had a Brazilian crank, german pistons and cylinders, German connecting rods, (Bruce checked these all out) a SCAT cam that Bruce recommended with a slight lift. My previously installed big nut trans was already cut for the bigger flywheel. I struggled at home with the end play. It always seemed to move on me. No patience. Bruce straightened all that out including the seal.
Oh and I forgot to mention, I went with MOFOCO DP (35.5/32) heads. Bruce can share that story later. So far they run great. He'll also have to comment on the $29.99 SVDA distributor (a throw in on a big order) I can't believe I'm running that runs flawlessly. I had several German ones to pick from, but Bruce tried it (more as a joke I think) and even he was surprised by the performance. Sometimes you get lucky.
I bought the 12V alternator kit as a conversion unit. Save your money and just buy the alternator. Everything that came in that kit, like Bruce said, was junk. The alternator shroud tin was garbage as was the alternator stand. All junk. It had to all be swapped for used German. The alternator does work, so as Bill Murray would say, "I guess I have that going for me."
Bruce insisted on me getting a proper '64 to '67 bus oil bath air cleaner set up. I had part of one and was able to source the rest and I'm glad I went with that instead of one that would require the base that my bus doesn't have. Bruce did an awesome job of putting a bracket in for that cleaner. Looks like it was there from day one.
I was reluctant to move away from 6 volt, as it's kind of defined me, but the danger I experienced trying to merge on freeway entrance ramps in a panel bus, even for the shortest travel distances, scarred me to 12 volts and an engine bigger than the 36HP's and 40HP's I was running. When you're limping along in the right lane after merging onto a freeway and your foot is on the floor and you're doing 43mph you get quite fearful when you see an 18 wheeler doing 65 coming barrelling up behind you with no room to merge left. Very scary. I remember one time I had to ditch it in the berm so I didn't get run over like a Buffalo Bill trying to tackle Derrick Henry.
I'm not a total phony though. I've still got my 6V beetle.
So I have the stock 40HP 6 volt engine saved away. Also the small nut split case trans is saved, and front drum brake set up, just in case a future owner wants to go back to full stock.
Sanding the crappy mud job from around the former cut in window holes will be a winter priority when Chuck comes over and upgrades my garage for 220 and a big compressor. And heat of course!
Then it will be time for paint and some kind of logo.
In any event, I can't thank Bruce enough. Not only do I have a great running early panel bus, I also got a great education that will help me understand things as I enjoy it!