My name is Tanner and I'm new to the forums here. I have a 1969 Baja bug that my dad and I rebuilt in 2009 to be my first car. I've been to Bug-a-Paluza with it two or three times. I actually met the president of Volks Folks and a few other members at KFC on East Brainerd some time back and had a nice little conversation. Anyways, around November of 2011, I decided that a 1600 wasn't big enough for me (and it was also leaking oil like crazy) so I started amassing parts for a 1915 motor. Last June or July, I had gathered all the parts and had given them to a guy in Georgia to build the engine. I think at that point he had been working on it for two months or so, and I was still driving my bug with the old 1600 in it. That June or July, I was just driving along when my clutch went out on me, so when we finally got it home, I decided that instead of just replacing the clutch, I would wait until the new engine was ready and just stick it in there. The new engine was finally finished, but at that point I was in the middle of lifting the bug about 3 inches (which took forever because of my lack of free time). So anyways, I'll fast forward to now... The bug is all lifted and looking good and the engine is in and running, I've gotten the carbs (dual Weber 40s) adjusted decently and it idles pretty good, but whenever I go to drive it, I get up to about 2500 rpm and it just won't go any higher. It just sputters and stays at 2500 and won't let me shift. I've been exchanging emails with a knowledgeable guy (John at vwparts.aircooled.net) and he suggested setting the timing at 12 BTDC because of the hemi cut head that are on it. I tried it and readjusted the carbs, but it still does the same thing. Now he's told me to check the compression which I have yet to do although I did just get a compression tester. I'm pretty tired of trying and failing to figure out the problem and just want to drive the dang thing again. Are there any members that are very knowledgeable about modified aircooled engines that might be able to help me out? It would really be awesome if I could just drop it off somewhere and someone fix it up for me, because I'm tired of trying to mess with it, but I don't know of any shops around here that do VWs, especially much modified ones. Thanks in advance! 

Here's my "build page" on the Samba: http://www.thesamba.com/vw/forum/viewtopic.php?t=489448&highlight=1915+build+advice

Travis,
Good point.
OP are you still running the mechanical Fuel Pump?

When you are at 2500 RPM does it start popping?
KC

My name is Tanner and I'm new to the forums here. I have a 1969 Baja bug that my dad and I rebuilt in 2009 to be my first car. I've been to Bug-a-Paluza with it two or three times. I actually met the president of Volks Folks and a few other members at KFC on East Brainerd some time back and had a nice little conversation. Anyways, around November of 2011, I decided that a 1600 wasn't big enough for me (and it was also leaking oil like crazy) so I started amassing parts for a 1915 motor. Last June or July, I had gathered all the parts and had given them to a guy in Georgia to build the engine. I think at that point he had been working on it for two months or so, and I was still driving my bug with the old 1600 in it. That June or July, I was just driving along when my clutch went out on me, so when we finally got it home, I decided that instead of just replacing the clutch, I would wait until the new engine was ready and just stick it in there. The new engine was finally finished, but at that point I was in the middle of lifting the bug about 3 inches (which took forever because of my lack of free time). So anyways, I'll fast forward to now... The bug is all lifted and looking good and the engine is in and running, I've gotten the carbs (dual Weber 40s) adjusted decently and it idles pretty good, but whenever I go to drive it, I get up to about 2500 rpm and it just won't go any higher. It just sputters and stays at 2500 and won't let me shift. I've been exchanging emails with a knowledgeable guy (John at vwparts.aircooled.net) and he suggested setting the timing at 12 BTDC because of the hemi cut head that are on it. I tried it and readjusted the carbs, but it still does the same thing. Now he's told me to check the compression which I have yet to do although I did just get a compression tester. I'm pretty tired of trying and failing to figure out the problem and just want to drive the dang thing again. Are there any members that are very knowledgeable about modified aircooled engines that might be able to help me out? It would really be awesome if I could just drop it off somewhere and someone fix it up for me, because I'm tired of trying to mess with it, but I don't know of any shops around here that do VWs, especially much modified ones. Thanks in advance! 

Here's my "build page" on the Samba: http://www.thesamba.com/vw/forum/viewtopic.php?t=489448&highlight=1915+build+advice

Tanner, After about 50 years of VW service , this sounds like a broken record to me. I read your build sheet and all the post about how to get it running. I'm afraid you have fallen into the "way,way,way" to much information syndrome . Look at it this way, You feel like crap so you go to the Doc and he gives you this red pill ,then as you leave he says you will also have to take this blue pill to counter the side effects of the red pill. Week goes by and you still feel bad. The Doc says you now need these yellow pills along with the red and blue pills. One week Doc now says stop taking the red pill and take these 3 black pills and on an on and you now have a counter full of expensive pills and you still feel like crap.  As far as getting that thing from  to run from anyone around here is problematic. If you do find someone, make good friends with him. Those modified boogers are like Army tanks. You work on them all week so you can drive them on Saturday.I have been there,done it. I know you didn't want to hear all of this but good luck.

Tanner, is the engine smooth from idle to 2500 RPM?

Thanks for the replies guys.

First of all, I've found at least part of the problem (hopefully the whole problem). I checked the compression and I got 95 across the board except #2 which was at 75. So now I just have to try to fix that.

Now to address the comments, the fuel is being delivered by a new rotary electric fuel pump which is regulated at 3-3.5 psi I think. I know it's right where a VW needs it anyways. So I think it should be good. It does run pretty smooth from idle to 2500 rpm where it starts sputtering, kinda popping I guess but not backfiring.

Ret.Bugtech, it most definitely is not what I was hoping to hear but pretty much what I expected. I realize now that I was overly eager to build this thing and get some "sweet horsepower" haha. I eventually just got too far into it so now it's either finish it or waste all the money I put into it. So hopefully I can get it going. I do wish I had stuck with the tried and true 1600 now though.

I would re-check valve lash. With the cam overlap spec's you have , compression WILL NOT be as high. (just one of those strange things) as a stock engine. Also your piston rings may not be "seated" yet. What method are you using to set your ign.timing ?  Explain in detail. This is VERY important.

I finished the motor in my car about two years ago.  Gene Berg high lift cam, straight cut timing gears, Italian Webers...etc...etc... I went through a lot to work the 'bugs' out, pun intended.  Do not be discouraged as this is part of the journey with high horse power VW's. I had a similar issue with the popping and it was all in the weber jets.  www.thesamba.com has some great forums on weber jets to get a starting point and I have a great carb book (I will need to dig it out to give you the title).  Still I bought some various jets and basically changed, adjusted, tried them out, then changed again.  I jetted down the primaries and totally changed the secondary configuration as I was getting too much fuel and not enough air when I got into the peddle.  Looks like a 009 distributor (no vacuum) timing might help this...again this will take some play to find the sweet zone (high output without excessive heating) as you are a long way from stock, the timing will not be what it was before.  When it is right it will be a real blast.

Just like I said " Work on the dang thing all week to be able maybe to drive it for a while on the week end"  Oh so much fun. Good luck.