Unleashing Power: The VW Okrasa Big Bore Engine

For enthusiasts of classic Volkswagen vehicles, the pursuit of enhanced performance, coupled with a deep respect for historical authenticity, often leads to legendary names like Okrasa. These weren't just performance parts; they represented a philosophy of meticulous engineering and a commitment to extracting every ounce of power from the humble air-cooled engine. Today, the spirit of Okrasa lives on through expertly rebuilt and restored engine kits, offering a unique blend of vintage charm and modern reliability. This article delves into the specifics of one such remarkable offering: the 36hp 1300cc "BIG BORE Torquer" engine kit, exploring the genuine VW blocks at its core, the intricate build process, and the impressive performance capabilities it unlocks.

The Foundation: Genuine VW Engine Blocks

At the heart of every "BIG BORE Torquer" engine kit lies a meticulously selected and prepared genuine Volkswagen engine block. The builder’s commitment to authenticity and quality begins with sourcing these crucial components. The primary choice for these engines comes from the sweet spot of VW's production, utilising authentic blocks manufactured between 1956 and 1960. These particular years are favoured for their proven durability and compatibility with the desired performance enhancements.

For the connoisseur seeking an even deeper connection to VW's early heritage, there's an exclusive option: earlier blocks dating from 1949 to 1955. These pre-A-pillar split-window era blocks carry a premium, reflecting their significant rarity and the inherent challenges in sourcing them due to supply and demand. This option allows for a truly period-correct build for those restoring earlier models or simply desiring that extra layer of historical fidelity. Regardless of the year, the selection process is rigorous, ensuring only blocks that meet stringent quality standards are chosen as the foundation for these high-performance units.

Block Preparation: A Masterclass in Precision

Once a genuine VW 36hp block is selected, it undergoes an exhaustive preparation process that leaves no stone unturned in the quest for perfection and long-term reliability. This isn't merely a clean-up; it's a comprehensive reconditioning designed to exceed original factory specifications. The steps are critical for the longevity and performance of the finished engine:

• Thorough Inspection: Each bare block is rigorously inspected for any signs of cracks, damage, or excessive wear that could compromise its integrity. Only blocks passing this initial scrutiny proceed.
• Hot Tank Cleaning: The block is subjected to a hot tank cleaning process, stripping away decades of grime, oil, and carbon deposits from every crevice, ensuring a pristine surface for subsequent operations.
• Surface Preparation: Critical mating surfaces, such as the cylinder decks, are meticulously prepared to ensure perfect sealing with the new cylinders and heads.
• Oil Galleys Drilled & Tapped: A crucial step for ultimate cleanliness and oil flow, all oil galleys within the block are precisely drilled and tapped. This allows for 100% positive cleaning, ensuring no contaminants remain to jeopardise the new components.
• Chemical Treatment: Following cleaning, the block undergoes a chemical treatment designed to restore its appearance to that of a new factory component, providing not just performance but also visual appeal.
• Precision Line-Bore: The main bearing tunnel is subjected to a precision line-boring process. This ensures that the crankshaft sits perfectly aligned within the block, critical for smooth operation, reduced friction, and extended bearing life.
• Cylinder Deck Surfacing: The cylinder decks are carefully surfaced, providing a perfectly flat and true platform for the new cylinder and piston assemblies, essential for optimal compression and sealing.
• High-Pressure Wash: A final high-pressure wash removes any remaining debris or machining residue, leaving the block impeccably clean and ready for assembly.

Only after this exhaustive preparation is completed is the block deemed ready for the assembly phase, using factory original German 14mm KAMAX/DURA Black Oxide hardware for a truly authentic and durable build.

The W.West "Okrasa" Engine Kit: Components and Craftsmanship

The core of this performance engine is the W.West "Okrasa" engine kit, a collection of high-quality components meticulously selected and balanced to work in harmony. This kit transforms the reconditioned block into a true "BIG BORE Torquer" engine, designed for both spirited driving and long-term reliability.

Powerhouse Components:

• Pistons & Cylinders: The "BIG BORE" aspect comes from the new 80mm piston/cylinder assemblies. These are carefully balanced, complete with rings, locks, and pins, ensuring smooth operation and optimal compression.
• Okrasa Style Heads: A pair of new W.West Okrasa style cylinder heads are central to the performance. These heads feature larger 33mm intake and 30mm exhaust valves, coupled with a competition "3-angle" valve job. This precise machining of the valve seats maximises airflow, allowing the engine to breathe more efficiently and produce more power.
• Bearings: All new main and rod bearings are installed, ensuring minimal friction and long life for the rotating assembly.
• Crankshaft & Rods: The engine features a reconditioned and balanced forged VW crankshaft, known for its inherent strength and durability. Paired with reconditioned and balanced VW connecting rods, this assembly forms the robust foundation of the engine's lower end.
• Flywheel: A resurfaced and balanced 180mm VW flywheel ensures smooth power delivery and proper clutch engagement.
• Camshaft: A new 36hp W.West performance camshaft with a bolt-on aluminium gear is installed. This performance camshaft is designed to optimise valve timing for improved power and torque delivery across the RPM range, making the "Torquer" name truly fitting.

Fuel & Air Delivery:

• Solex Carburetors: A pair of new 32mm "Solex" carburetors are supplied, pre-jetted precisely to Okrasa specifications. This ensures optimal fuel-air mixture right out of the box, tailored for the engine's performance characteristics.
• Air Cleaners: New wire mesh air cleaners provide excellent filtration while maintaining a period-correct appearance.
• Intake Manifolds: A pair of new W.West "Okrasa" intake manifolds feature a balance tube, critical for even fuel distribution between cylinders. Red neoprene connectors with correct "buckle-strap" clamps complete the robust intake system.
• Linkage Kit: A complete W.West linkage kit is included, ensuring precise and reliable operation of the dual carburetors.
• Essential Hardware: Fuel line, intake to manifold gaskets, flywheel gland nut, and all necessary nuts/bolts for installing the carb kit are provided, ensuring a complete and ready-to-install package.

It's important to note that the customer is responsible for supplying and installing their own sheetmetal, generator, fuel pump, distributor, etc. This approach allows for cost savings and customisation while focusing the builder's expertise on the core engine assembly.

Elevating Performance: Optional Upgrades

While the standard "BIG BORE Torquer" kit offers impressive performance, several optional upgrades are available for those seeking even greater capacity, longevity, or customisation. These options are carefully selected to complement the engine's design and further enhance its capabilities.

Key Options Include:

• Gene Berg "Deep Oil" Sump: An aluminium Gene Berg "deep oil" sump can be installed, significantly increasing the engine's oil capacity. More oil means better cooling and lubrication, particularly beneficial for spirited driving or in hotter climates, extending engine life.
• Gene Berg "Full Flow" Filter Kit: For unparalleled oil filtration, a Gene Berg "Full Flow" filter kit is highly recommended. This system ensures 100% of the engine's oil is filtered, removing microscopic contaminants that can cause wear, providing maximum protection for internal components.
• Forged Stroker Crankshaft: For those craving more displacement and torque, a balanced, forged 69.5mm stroker crankshaft is available. When combined with the 80mm bore, this results in a 1400cc engine (80mm bore x 69.5mm stroke). A stroker crankshaft increases the engine's displacement by lengthening the piston's travel, leading to a noticeable increase in torque and horsepower. This option often comes with an 8-dowelled and balanced flywheel for enhanced durability and power transfer.

These options allow enthusiasts to tailor their engine to specific performance goals or driving conditions, ensuring that the "BIG BORE Torquer" can be perfectly adapted to their needs.

The Build Process: Transparency and Expertise

The journey from a bare block to a complete "BIG BORE Torquer" long block is a testament to the builder's dedication and decades of experience. The process is designed to be transparent and reassuring for the customer, providing peace of mind throughout the build.

A $1500 deposit secures a place in the build schedule, with the remaining balance due upon completion. The current lead time for these meticulously crafted long blocks is remarkably efficient, typically only 10-15 working days. What truly sets this service apart is the unparalleled transparency offered: a private online photo album is created for each customer. This album allows you to privately view your engine's build progress from the initial bare block right through to the completed long block or engine. This eliminates any guesswork about the components used or the quality of the work, providing clear visual evidence of the "BIG BORE" piston/cylinder assembly, new or rebuilt heads, line-boring, and every other critical step.

This level of detail and openness is a direct reflection of the builder's extensive experience – over 45 years of hands-on work exclusively on air-cooled VW engines. This specialisation ensures that every engine is machined in-house to precise tolerances and built correctly, with first-time quality that only such a depth of experience can provide.

Shipping Your Masterpiece

Once your W.West "Okrasa" 36hp long block engine kit is complete, shipping is handled with the same level of care and efficiency. Whether it's across the street or across continents, the builder has established reliable and cost-effective shipping solutions.

For shipments within the USA, highly competitive rates are secured through Yellow Freight, with shipping typically starting around $175. For international enthusiasts, worldwide shipping is facilitated through Stratus Logistics in Long Beach, CA. Engines are carefully packed in overseas U.S. Customs Approved HT shipping boxes, specifically designed to protect these valuable components during transit. This global reach ensures that classic VW enthusiasts anywhere in the world can access these exceptional engine builds.

The 36hp Challenge: Durability and Performance

The mention of the "36hp Challenge" provides a fascinating insight into the extreme capabilities that can be coaxed from these vintage platforms. This challenge, often associated with land speed records, pushes the boundaries of what a 36hp VW engine can achieve while retaining a stock external appearance.

A specific example cited involved a 1415cc engine (77mm bore x 76mm stroke) for the 2005 Hot VW's Land Speed 36 HP Challenge. This engine, built by Tom Bruch Systems, achieved an impressive 81.22 MPH in the standing mile, setting an H/GSR record. It was a "stroker motor," featuring a 76mm German stroker crank, modified 36hp case for windage and stroker clearance, and heavily modified heads with Okrasa 30mm intake valves. Crucially, the inquiry regarding "crank failure" in the 36hp challenge highlights a common concern for high-performance builds. However, in the cited example, the issue was not a crank failure but rather an oiling system problem—specifically, an oversized oil pump causing excessive oil leakage due to the pressure relief remaining open. This underscores that while pushing boundaries, attention to every detail, including lubrication, is paramount for engine survival.

The forged VW crankshaft used in the "BIG BORE Torquer" kit, along with meticulous balancing and reconditioning, provides a robust and reliable foundation, even for those considering future performance enhancements. The "36hp Challenge" demonstrates the incredible potential for power and speed latent within these seemingly humble engines when built with expert knowledge and high-quality components.

Understanding the Dual Port 36hp Engine Kit

While the focus of this article is on the "BIG BORE Torquer" kit, it's worth briefly touching upon the "Dual Port 36hp Engine Kit" as it represents another significant upgrade path for 36hp engines. This kit, engineered to original Oettinger standards by Wolfsburg West, offers a comprehensive solution for converting a single-port 36hp engine to a dual-port configuration. Dual port heads allow for improved airflow and better fuel atomisation compared to single port designs, leading to increased power and efficiency.

Key components of such a kit typically include OEM manufactured cylinder heads (dual port), reproduction Solex 32PBIC carburetors, and original style linkage. While offering excellent performance benefits, it's important to note that conversions to dual port sometimes require minor modifications, such as to the rain gutter on convertible models, or air cleaner elbows for trucks, Karmann Ghias, or coachbuilt models. This highlights the varied approaches to performance upgrades within the classic VW community, with the "BIG BORE Torquer" offering a specific, high-torque, big-bore Okrasa-style solution.

Frequently Asked Questions About VW Okrasa Engines

Conclusion: A Legacy of Power and Precision

The W.West "Okrasa" 36hp 1300cc "BIG BORE Torquer" engine kit represents more than just a collection of parts; it's a meticulously crafted powerhouse built upon decades of specialised experience. From the careful selection and rigorous preparation of genuine VW blocks to the inclusion of high-quality, balanced components and the option for further performance enhancements, every aspect of these engines is designed for superior performance and lasting durability. The transparency of the build process, coupled with the builder's profound expertise in air-cooled VW engines, offers enthusiasts unparalleled peace of mind.

Whether you're restoring a classic Beetle, Karmann Ghia, or simply seeking to inject new life and exhilarating performance into your vintage VW, this Okrasa-style engine provides an authentic and powerful solution. It's a true testament to the enduring appeal of the air-cooled Volkswagen, reimagined for the modern enthusiast seeking both historical accuracy and a thrilling driving experience. Embrace the legacy of Okrasa and feel the remarkable difference a truly custom-built engine can make.

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