1600 CC VW Air Cooled
So, the engine. At first I ordered the 1/2 VW engine plans from great plans. I wanted to build the half case version, but realized that it will leave me with no starter or alternator, It is also complicated to balance the crankshaft. So I decided to build a stock 1600 cc VW air cooled engine. The idea was to get everything together for a stock engine then move from there.
1971 AE Engine Case
Things to consider, a new dual port aluminum case will cost you around $900.00. They also weight a bit more than the magnesium ones do, consider that if money is not an issue. If you are trying to keep everything cheap. Consider buying an engine from the scrap yard. You want an AE case because they have a dual port intake. They are supposed to be made with a better magnesium allow as well. There are other serial number cases that will suit the needs for the conversion. Google them.
The problem of used cases:
Ditch Craigslit. I spend over 2 weeks following leads of people who would never answer their adds. Since the original VW beetle is now over a century old. It is harder to find one on a pick and pull too. I found a specialty place called "Dick's U-Pull - It" here in WA state that only deals with older cars and hot rods. At the time they had over six beetles in good condition and was the only place I found to have any.
According to some research I did, as the magnesium heats above the recommended engine temperatures it can only withstand so many "cycles" of this thermal expansion before it renders the case useless. You will probably not have any engine history of a pick an pull engine. Just use your best judgment, but be advised you might be buying junk.
The case will most likely need to be line bored and thrust cut. Even if the rear main saddle looks fine, try and do it, also remember it is a good idea to get your bearings from the same place that does the machining.
Rear main saddle
I found my engine the case could be salvage. The guy at the machine shop mention that it was already line bored before. (They mark it on the back of the case.)
Almost none locally machines VW cases. As with finding the cases, machine shops that want to touch these are only a handful. Mostly in California. thesamba.com is a good place to start. I sent mine to the east coast with evwparts.com.
The good things about used cases:
You will most likely just buy the whole engine assembly. That means if you are lucky and find an engine that is not rusted out completely you will have all the internals, Crankshaft, Rods, Pistons, Camshaft and Cylinder heads. I paid $191.45 for mine with taxes. I could only salvage the crankshaft along with the case.
If you don't mind doing some lifting on your own.