Posted by: Toby - 01 August 2006 16:14:20
I am currently rebuilding a 1500cc engine that was in my 1964 beetle. I have now discovered that i need to replace the flywheel as the teeth are badly damaged. I have been told that there are 3 different sized flywheels: 200mm 12v, 180mm 12v and a 180mm 6v. I have measured my flywheel and it is 180mm, as this car was originally 6v (now converted to 12v) I am assuming that I need the 180mm 6v? Although I have since been told that I could use the 180mm 12v, grind out a lug in the gearbox and replace the starter motor with the 12v version. Seeing the 180mm flywheel 6v or 12v seem to be like rocking horse poo, can I use the 200mm and replace the clutch and starter motor? Any advise would be greatly appreciated. :?

Posted by: six-o-one - 01 August 2006 17:04:34
Hi Toby, welcome to the forum. :D Are you running the original 6 volt starter on 12 volt? You can count the teeth on the flywheel, 6 volt will have 109 teeth, 12 volt will have 132 teeth. If you swap to a 200mm clutch and flywheel you will have to grind the inside of the gearbox slightly to get the flywheel to turn. When you offer-up the engine with the bigger flywheel, turn the engine over by hand and the flywheel will mark the bell housing where it's touching. I think the bush in the gearbox for the end of the 12v starter is different too?

Posted by: Toby - 01 August 2006 17:41:49
Thanks for help, much appreciated!! :D

Posted by: Toby - 02 August 2006 09:16:59
After checking the flywheel it has 109 teeth, so I think the previous owner must have changed the original 1200 lump over to the 1500 and I suspect to save time he used the original flywheel. So am I now correct in saying that the flywheel for a 1500cc engine is the 200mm? And that in order to switch it over correctly I will need to buy the following: 200mm flywheel, 200mm clutch, 12v starter motor and bush?

Posted by: six-o-one - 03 August 2006 11:35:46
This is from memory so don't quote me... I think some of the first 1500 beetles from '67 were 6 volt and some were 12 volt but retained the 180mm 109 tooth flywheel and had a special 12 volt version of the 6v style starter motor! :? later 1500 engines would have the 200mm clutch. I think there may be a difference with the clutch release bearing on your gearbox too? It might be worth talking to someone like Barclay at [url=https://www.status-vw.co.uk]Status VW parts[/url]. He has the 6 volt style 12 volt starters if you do want to keep a 180mm clutch but should know what else you need to change if you go the 200mm route.