Engine Case, Aluminum, 90.5/92 for 8mm Studs Sand Sealed

OVERVIEW

When you are pushing the limits of air-cooled performance, the foundation of your build is everything. This EMPI Aluminum Engine Case is the definitive upgrade for serious VW enthusiasts who have outgrown the limitations of vintage magnesium cases. Engineered from high-quality aluminum alloy, this case offers significantly better heat dissipation and structural rigidity than stock components. Unlike older cases that suffer from pulled head studs and warped main saddles under high stress, this aluminum powerhouse is designed to handle the increased torque and cylinder pressures of high-displacement engines. It comes pre-machined for a 90.5mm or 92mm bore, making it the perfect starting point for a 1776cc, 1914cc, or 2110cc build. The sand-sealed snout is a critical feature for off-roaders and performance street builders alike, providing a superior barrier against dust and debris that typically destroys main bearings.

Beyond its raw strength, this case is packed with competition-level features that usually require expensive trips to the machine shop. The "bubble top" raised roof design provides internal clearance for massive stroker cranks up to 86mm, while the shuffle pins on all main saddles ensure the case halves remain perfectly aligned under high-RPM vibration. We have also addressed the common failure points of the Type 1 engine by reinforcing the area behind the number three cylinder and beefing up the head stud bosses. Oiling is also a top priority; this case features a universal dual-bypass design and is already drilled and tapped for full-flow oiling with a plug included. The main oil gallery is also tapped for easy cleaning during the assembly process. If you are building a high-performance engine that you expect to last, this EMPI aluminum case provides the "race-ready" durability and precision machining required for a world-class air-cooled masterpiece.

FITMENT

This engine case is designed for Type 1 based air-cooled engines and is compatible with the following models (assuming Type 1 engine configuration):

• Volkswagen Beetle: 1950 through 1979 (Sedan and Convertible)
• Volkswagen Karmann Ghia: 1956 through 1974
• Volkswagen Type 2 Bus: 1950 through 1971
• Volkswagen Thing: 1973 through 1974
• Custom Applications: Ideal for Sand Rails, Dune Buggies, and Kit Cars using a Type 1 VW drivetrain.

SPECS

• Material: High-Strength CNC Machined Aluminum Alloy
• Cylinder Bore Size: 90.5mm / 92mm (Pre-machined)
• Head Stud Size: 8mm (Steel Case Inserts Installed)
• Crankshaft Clearance: Clearanced for up to 86mm Stroke
• Main Saddles: Shuffle Pinned for maximum alignment and rigidity
• Oiling System: Universal Dual-Bypass Design
• Full Flow: Drilled and Tapped with Plug included
• Oil Gallery: Main gallery tapped and plugged for easy maintenance
• Crankshaft Nose: Machined for Sand Seal (requires sand seal pulley/crank setup)
• Design: Bubble Top / Raised Roof for stroker clearance
• Reinforcements: Filled area behind #3 cylinder and reinforced stud bosses
• Cam Plug: Grooved for superior sealing
• Weight: Approximately 42 lbs (Bare Case) / 44.8 lbs (Shipping Weight)

PRO TIPS

Pro Tip 1: Prep Like a Professional. Even though this case is brand new and CNC machined, you should NEVER assemble an engine straight out of the box. Because the main oil galleries are already tapped and plugged, you must remove those plugs and run a galley brush through every passage with hot soapy water. Manufacturing debris or shipping dust can hide in the oil channels. Thoroughly dry the case and immediately coat the machined surfaces with a light film of oil to prevent any surface oxidation before you begin your final assembly.

Pro Tip 2: Plan for Shroud Clearance. This case features the "Bubble Top" or raised roof design to allow for long-stroke crankshafts. While this is an incredible performance benefit, it does increase the external dimensions of the case slightly in the center. You will likely need to perform minor trimming or clearancing on your stock-style fan shroud to get it to sit flush against the case. Do a "dry fit" of your tinware before you have the engine fully assembled to ensure everything lines up without scratching your fresh paint or powder coating.

Pro Tip 3: Understanding the Sand Seal. This specific case is machined for a sand seal at the pulley end. This means you cannot use a standard stock-style crankshaft pulley. You must use a pulley designed for a sand seal, or a sand seal kit that includes the proper spacer and seal. This setup is highly recommended for any engine that will see dirt, sand, or high-performance street use, as it replaces the original "oil return screw" design with a modern lip seal that prevents oil leaks and keeps contaminants out of your bottom end.