The basics of my AH206906 rebuild.
This is a small subset of my spreadsheet where I plan out where each part needs to come from and keep track of the vendor, price, part #, etc.
Reusing the AH case and not having any other problems should put the engine rebuild costs at $2,726.76.
With many of the crate long blocks out there starting at $2500 for a basic 1600cc engine, I think the $2,726.76 parts cost will hopefully be the max for this.
If I had reused some of the AH engine parts, which I would have if I had a air-cooled knowledgeable machine shop around to deal with a lot of things, I would have spent a lot less.
However, when I decided to do what I’m calling basically “Stock Plus” with GTV-2 heads, a counter-weighted SCAT crank, a new lightened flywheel, better cam and 1.25 rocker arms, basic dual carbs, etc. I know I would have to put out some money for the SCAT and other better performing parts.
I could seeing to spend another few dollars here and there. Hell, I may even not use some of these parts and reuse some of the original 1974 AH206906 engine stock parts. I do have that AR engine I need to accumulate tins and such for. I’m hoping I can test and rebush some of the alternators I have too.
| 3/22/2019 | AH206906 Rebuild |
| Part | Vendor Part Description |
| Alternator – Alternator | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Alternator – Oil Filler | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Alternator – Stand | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Alternator – Stand Gasket | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Alternator – Strap/Clasp | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Carb – Carburettor | Dual 34 EPC 34 Carburetor Kit |
| Carb – Gasket | Dual 34 EPC 34 Carburetor Kit |
| Case – Block | Reuse from AH206906 |
| Case – Case Savers | Case Saver Insert, 12mm x 8mm × 1 |
| Case – Cylinder Studs | Cylinder Head Stud Kit 8MM |
| Case – Full Gasket Set | PERFORMANCE ENGINE GASKET SET |
| Case – Hex Style Oil Relief Screws | Oil Piston Relief Plug, Hex x 2 |
| Case – HW Kit | Deluxe Engine Hardware Kit 8MM |
| Case – Main Journal Bearings | Type 1 Main Journal Performance Bearing Set |
| Case – Main Journal Dowel Pins | SET OF 5 DOWEL PINS FOR MAIN BRG |
| Case – Trans to Engine Bolts/Studs | Engine Mounting Bolt Kit × 2 |
| Crank – Connecting Rod Bearings | KS Kolbenschmidt Rod Bearings |
| Crank – Connecting Rod Bushings | Connecting Rods, Stock 1600cc, New |
| Crank – Connecting Rods | Connecting Rods, Stock 1600cc, New |
| Crank – Crank Pulley | VW Crank Pulley, Solid, Black Markers |
| Crank – Crank Pulley Bolt | Mighty 8.8 Crank Bolt and SS Washer |
| Crank – Crank Pulley Washer | Mighty 8.8 Crank Bolt and SS Washer |
| Crank – Crankshaft | 69MM Volksaver 8 Dowel Crankshaft |
| Crank – Timing Gears and Spacers | Crankshaft Gear Assembly |
| Cylinders Heads – Heads | EMPI GTV-2 Dual Port Cylinder Head – Single Hi-Rev Springs 98-1331-B |
| Cylinders Heads – Shims | Not needed on this specific build |
| Drivetrain – Clutch – Friction Disk | LuK 17-013 Clutch Set |
| Drivetrain – Clutch – Pressure Plate | LuK 17-013 Clutch Set |
| Drivetrain – Clutch – Throwout Bearing | LuK 17-013 Clutch Set |
| Drivetrain – Flywheel | 200MM CAST IRON FLYWHEEL – LIGHTENED / BALANCED / 8 DOWELED |
| Drivetrain – Flywheel 8-Dowel Gasket | 8 Dowel Flywheel Gaskets (Set of 10) |
| Drivetrain – Flywheel Dowel Pins | 69MM Volksaver 8 Dowel Crankshaft |
| Drivetrain – Flywheel Gland Nut | Chromoly 1 1/2″ Hex Gland Nut & Heavy Duty Washer Set |
| Drivetrain – Flywheel Gland Nut Washer | Chromoly 1 1/2″ Hex Gland Nut & Heavy Duty Washer Set |
| Drivetrain – Flywheel O-Ring | FLYWHEEL O-RING SEAL |
| Drivetrain – Flywheel Seal | Elring Flywheel Seal |
| Drivetrain – Flywheel Shims .24MM | Reuse from AH206906 |
| Drivetrain – Flywheel Shims .30MM | Reuse from AH206906 |
| Drivetrain – Flywheel Shims .32MM | Reuse from AH206906 |
| Exhaust – Heat Exchanger – Left | Not needed on this specific build |
| Exhaust – Heat Exchanger – Right | Not needed on this specific build |
| Exhaust – J-Pipe – Left | J-Pipe, Left And Right |
| Exhaust – J-Pipe – Right | J-Pipe, Left And Right |
| Exhaust – Merged Header | Not needed on this specific build |
| Exhaust – Muffler | EMPI – PEA SHOOTER – 2-TIP EXHAUST |
| Exhaust – Muffler Gasket Set | VW Muffler Installation Kit, Type 1, 1200-1600cc Beetle |
| Exhaust – Muffler Tail Pipes | Not needed on this specific build |
| Fuel – Fuel Pump | Brosal Stock Fuel Pump |
| Fuel – Fuel Pump Flange | Fuel Pump Flange |
| Fuel – Fuel Pump Rod | Reuse from AH206906 |
| Fuel – Rubber Hose | 3ft Armor Mark 1/4″ fuel line |
| Fuel – Steel Line – Pump to Tunnel | Reuse from AH206906 |
| Ignition – Coil | Reuse Bosch 00012/9220081083 Ignition Coil from 10/4/2017 |
| Ignition – Distributor | EMPI Generic 009 Distributor |
| Ignition – Distributor Clamp | Reuse from AH206906 |
| Ignition – Distributor Drive Gear Pinion | Reproduction Distributor Drive Gear Pinion |
| Ignition – Distributor Drive Washers | Reuse from AH206906 |
| Ignition – Distributor O-Ring | VW Distributor Shaft O-ring, Beetle |
| Ignition – Distributor Spring | Distributor Spring, Stock |
| Ignition – Spark Plug Wires | Bosch 09001 Premium Spark Plug Wire Set |
| Ignition – Spark Plugs | NGK B6HS Spark Plug, 14mm 1/2 inch Reac |
| Oil – Breather Kit | Not needed on this specific build |
| Oil – Drain Plate | Reuse from AR039953 |
| Oil – Gallery Plug Kit | Oil Gallery Plug Kit |
| Oil – Oil Cooler | Reuse from AH206906 |
| Oil – Oil Cooler Seals | PERFORMANCE ENGINE GASKET SET |
| Oil – Pressure Switch | Oil Pressure Sending Unit |
| Oil – Pump | Schadek Oil Pump H-D 26MM Gears |
| Oil – Pump Cover Plate | Billet 8MM Oil Pump Cover |
| Oil – Pump Gasket Inner | Schadek Oil Pump H-D 26MM Gears |
| Oil – Pump Gasket Outer | Schadek Oil Pump H-D 26MM Gears |
| Oil – Pump Seal 8mm Nuts | Oil Pump Sealing Nuts (4 Pack) |
| Oil – Strainer | Reuse from AH206906 |
| Other – Thermostat | THERMOSTAT – (Mexico Style) |
| Other – Thermostat Bracket | THERMOSTAT BRACKET |
| Other – Thermostat Rod | Reuse from AH206906 |
| Pistons and Cylinders – Copper Gaskets | Not needed on this specific build |
| Pistons and Cylinders – Set of 4 | 87MM 1641CC SLIP IN PISTON & CYLINDER |
| Tin – Accelerator Cable Tube | Reuse from AH206906 |
| Tin – Alt/Gen Cover | IAP Performance AC903900EC 60 Amp Alternator Kit for VW Beetle |
| Tin – Cylinder Air Vanes Assembly | Not needed on this specific build |
| Tin – Cylinder Deflectors, Bottom | Not needed on this specific build |
| Tin – Cylinder Head Internal Deflector | Reuse from AH206906 Heads |
| Tin – Cylinder Heads | BLACK DUAL PORT CYLINDER TIN |
| Tin – Doghouse Shroud | Reuse from AR039953 |
| Tin – Doghouse Shroud Rubber Seals | Reuse from AH206906 |
| Tin – Fan | LATE VW TYPE 1 ENGINE FAN, 1971 – 1979 |
| Tin – Fan – Hub Kit | VW Type 1 Fan Hardware Kit |
| Tin – Fan Shroud – Throttle Tube Seals | PLUG THROTTLE TUBE HOLE BEETLE 71-79 |
| Tin – Fan Venturi Ring | Not needed on this specific build |
| Tin – Front Firewall | Reuse from AH206906 |
| Tin – Heater Box (3 piece) | 3 PIECE HEATER BOX TIN |
| Tin – Hoover Bit | Hoover Bit |
| Tin – Ignition – Coil Cover | Reuse from AR039953 |
| Tin – Oil Cooler Tin Lower Seals | Lower Oil Cooler Tin and Seals |
| Tin – Oil Cooler, Lower | Lower Oil Cooler Tin and Seals |
| Tin – Oil Cooler, Upper | Reuse from AH206906 |
| Tin – Rear Engine | VW Rear Engine Tin, Black, w/ Hose, w/o Heat Riser |
| Tin – Rear Pulley | VW Engine Pulley Breast Plate Tin, Black |
| Tin – Screws 6MMX12MM | Reuse from Consumables |
| Tin – Seal – Front Fuel Line Grommet | Fuel Line Grommet for Front Tin |
| Tin – Small Deflector Left | Not needed on this specific build |
| Tin – Small Deflector Right | Not needed on this specific build |
| Tin – Type 3 Cyl Air Deflector (optional) | Type 3 Cooling Tin, Pair |
| Tin – Valve Cover | Valve Cover Kit, Bolt On, with Hardware and Gaskets, Aluminum |
| Tin – Valve Cover Bails | Valve Cover Kit, Bolt On, with Hardware and Gaskets, Aluminum |
| Valvetrain – Camshaft | Scat VW 20050 CAMSHAFT & ACC Cam Kit with C20 Cam – Single Springs |
| Valvetrain – Camshaft Bearings | Silverline Doube Thrust Cam Bearings |
| Valvetrain – Camshaft Gear | Scat VW 20050 CAMSHAFT & ACC Cam Kit with C20 Cam – Single Springs |
| Valvetrain – Camshaft Gear Bolts | Camshaft Gear Bolts and Washers |
| Valvetrain – Camshaft Lifters | Scat VW 20050 CAMSHAFT & ACC Cam Kit with C20 Cam – Single Springs |
| Valvetrain – Camshaft Plug | Cam Plug (with O Ring) Billet |
| Valvetrain – Pushrod Tubes | PUSH ROD TUBE x 8 |
| Valvetrain – Pushrods | Reuse from AR039953 |
| Valvetrain – Rocker Arms | Rocker Arms, 1963-1979 Forged Assemblies 1.25 Ratio, Pair |
| Valvetrain – Rocker Arms – Feet | Rocker Arms, 1963-1979 Forged Assemblies 1.25 Ratio, Pair |
| Valvetrain – Rocker Arms – Shaft | Rocker Arms, 1963-1979 Forged Assemblies 1.25 Ratio, Pair |
| Valvetrain – Valve Lash Caps | Not needed on this specific build |
| Valvetrain – Valve Springs | EMPI GTV-2 Dual Port Cylinder Head – Single Hi-Rev Springs 98-1331-B |