Pushrod Assembly Tool Air-cooled VW Motors

OVERVIEW

When you''re building a high-performance air-cooled Volkswagen engine, precision is the name of the game, especially when it comes to your valve train. The EMPI Pushrod Assembly Tool (16-9610-0) is a professional-grade solution designed to take the guesswork out of assembling custom-length 3/8-inch diameter pushrods. Whether you are running a high-lift cam, high-ratio rockers, or have milled your cylinder heads, standard pushrods often won''t provide the correct geometry. This tool allows you to seat the ends into your cut-to-length aluminum or chromoly pushrod tubes with absolute accuracy, ensuring that the tip is perfectly centered and seated every single time. By providing a stable and aligned platform for assembly, you eliminate the risk of marring the tips or causing slight bends in the tubing that can lead to catastrophic engine failure at high RPMs.

This tool is a meticulous reproduction of a classic design, updated for the modern engine builder who demands durability and ease of use. Manufactured from high-quality tool steel and finished with a rugged black oxide coating for superior corrosion resistance, it is built to survive the harsh environment of a busy machine shop or a dedicated enthusiast''s garage. It is versatile enough to be used in a lathe for the ultimate in precision or utilized with standard hand tools for those building at home. When used in conjunction with a pushrod measuring tool, this assembly jig ensures that every pushrod in your set is identical in length and structural integrity, providing the balanced valve action necessary for maximum horsepower and longevity in your Type 1, Type 2, or Type 3 power plant. Don''t settle for "close enough" when the health of your engine is on the line.

FITMENT

• Volkswagen Type 1: Beetle, Bug, and Karmann Ghia (All years with air-cooled upright engines)
• Volkswagen Type 2: Bus, Transporter, Station Wagon (1200cc, 1500cc, and 1600cc engines)
• Volkswagen Type 3: Squareback, Fastback, and Notchback models
• Volkswagen Type 181: The Thing
• Custom Applications: Ideal for Sand Rails, Dune Buggies, and Trikes utilizing VW-based air-cooled engine cases
• Pushrod Type: Specifically designed for 3/8-inch diameter cut-to-length aluminum or chromoly pushrods

SPECS

• Manufacturer Part Number: 16-9610-0
• Material: Hardened Tool Steel
• Finish: Industrial Black Oxide Coating
• Total Length: Approximately 13.5 Inches
• Total Width: Approximately 1.25 Inches
• Compatibility: 3/8" Diameter Pushrod Tubes
• Design: Precision-machined for repeat accuracy
• Tool Type: Assembly jig for press-fit pushrod ends
• Weight: 1.14 lbs

PRO TIPS

Tip 1: Perfect the Measurement Before Assembly

Before you ever touch the assembly tool, you must use a dedicated pushrod measuring tool (such as the EMPI 16-9600-0) to find your ideal length. Install your rockers and adjust the measuring tool until you achieve a perfect 90-degree angle between the rocker arm and the pushrod at half-lift. Once you have this measurement, subtract the thickness of the pushrod tips to determine your exact tube cut length. Remember the old adage: measure twice, cut once. Even a millimeter of variance can cause uneven wear on your valve guides and rocker pads.

Tip 2: Prepare the Tube Ends for a Seamless Press

After cutting your chromoly or aluminum tubes to length, it is vital to de-burr the inside and outside edges of the cut. Use a small chamfering tool or a fine-grit sandpaper to ensure there are no sharp edges or metal shavings left behind. A clean, slightly beveled edge allows the tip to seat into the tube much more smoothly when using the 16-9610-0 tool. If you are using chromoly pushrods, a tiny drop of red Loctite or a similar high-strength sleeve retainer on the shank of the tip can provide extra security against the tip loosening during high-heat cycles.

Tip 3: Utilize Thermal Expansion for Easier Installation