1	2008 Type 4 Store Engine Kit Program A comprehensive look into the program that enables novice enthusiasts to attain professional results.
2	Introduction Before going further into this presentation please understand that the term “Engine Kit” is used very loosely in the automotive engine world…….
3	"The engines that will be..." The engines that will be explored within this presentation are best described as “Unassembled Engines” as they are professionally designed, well proven and very effective.
4	"We call these" We call these “Kits”……… Because thats simple….
5	"These are NOT" These are NOT items that have been taken off shelves, re-boxed and shipped away with unknown results.
6	"These combinations feature professional configuration..." These combinations feature professional configuration as well as lab and field testing and have helped to breed the Aircooled Technology Pedigree over the past decade.
7	"As we refer to these..." As we refer to these “Unassembled Engines” as Kits please keep in mind that they are much more than a few boxes of parts, or the conventional “Engine kit”. Jake Raby President, Raby Enterprises Inc.
8	History of the Engine Kit program It’s been almost a decade since the first Aircooled Technology engine kit was created. Back in those days we didn’t have a retail entity and engine kits were treated much like our turnkey “Custom” engines. Back then we also didn't sell parts, but were constantly asked to offer them so one day someone asked me to create an engine “kit” for them with the same detail that went into my turn key engines. That day the Aircooled Technology engine kit program was born. Since then hundreds of novice enthusiasts have completed their own engine build project with confidence. Most of these individuals did this in the comfort of their own garage without the need of any special tools or equipment, with little or no previous experience.
9	It can be done. YOU CAN DO IT! The engine kit program we have created couples our vast Type 4 engine developmental experience and support with the assembly procedures of the individual enthusiast. This gives the novice enthusiast that would generally be challenged to even complete their first build successfully without failure, the ability to literally do the job as thoroughly as a professional.
10	"These kits are NOT designed..." These kits are NOT designed to be assembled by local shops or other engine companies, in fact we won’t supply kits that are to be assembled by anyone other than the purchaser. Our Aircooled Technology division offers Turn Key engines that are the latest and greatest available, should you desire to purchase an engine outright, already assembled, proven and pedigreed.
11	It can be done. YOU CAN DO IT! Our entire kit program is designed for the novice, the first timer or better known as the “Newbie”. Here we don’t care if you have never built a Type 4 engine before, or if this is your 20^th project, it’s a non issue! We treat every purchaser equally and will never make you feel “dumb” and we’ll never treat your questions like they aren’t important to us. This is because we are very accustomed to working with “newbie” builders and helping them overcome their mechanical fears and inabilities. In some instances we actually prefer that the purchaser hasn’t been subject to other engines or bad habits because these engines and our program are very different from any other that most people will experience in their mechanical explorations in life. Most find it interesting that our most successful builds were done by first timers with zero experience, these people have ranged in age from 15 years old to 77 years young and from all walks of life and educational backgrounds that can be imagined. With our support, and the procedures and reference materials offered to the kit assembler from our comprehensive program you truly can do a professional quality engine build in your garage. We do not exaggerate when we state: It can be done. YOU CAN DO IT!
12	What makes it a “Kit” Well, this question really should be “What makes it an “unassembled engine”, but that’s too confusing…. Each engine kit is complete with ALL mechanical, internal components to complete a “Longblock” assembly. This means that your kit will come configured, balanced, clearanced and ready for all internal components to be assembled. This means that there will be no need to purchase any other components from any other sources to complete the kit build and this is priceless. To top off our kits we even include all our sealants for various areas of the engine as well as enough engine oil for break in and the first oil service. The best way to explain the completeness of our engine kits is ”we include everything from main bearings to valve adjusters with no aspect of the components in between overlooked”…. After the engine kit is assembled the builder can simply dress the engine with induction, ignition, exhaust and cooling sub systems for a complete engine. Of course we offer recommendations on the best arrangements of these units for each combination and share those in detail with each potential kit purchaser that takes the time to read our information in depth, thus eliminating guesswork. Look further in this presentation for component details for each kit..
13	POWER OUTPUT!!!! Our engine kits are all based on more overall performance. We look at engines in the “big picture” and more performance doesn’t just mean “Horsepower”. We develop engines for efficiency, this means not only more POWER but also cooler running temps, better MPG, quieter operation and smoother running with NO LOSS of reliability or longevity. Sounds like a dream, doesn’t it? It’s a reality and YOU can create it. Detailed output of each engine kit offering will be available at the close of this presentation.
14	What “if” I have a 1.7 or 1.8 core engine?? Do I have to use a 2.0? NO!!!!! The beauty of our kit design is the fact that ANY Type 4 engine, of any stock size can be used to create one of our kits!! All Type 4 engine cases are created equally in our opinion. Those with smaller base engines won’t face more difficult builds when using our kits, this is designed into the program! NO WORRIES!!!!!
15	Kit Component Familiarization In the following pages we will examine the major components that can be found in all Type 4 Store Engine Kits with the aid of pictures and text. Please note that these are general pictures used only as educational tools to familiarize the potential buyer with the general parts included in each kit, despite displacement of output level. These may not be the same as those that are actually included in your particular kit, both dimensionally and cosmetically. This is due to variances in each kit that characterize it as an “Engineered” unit, configured for a specific application.
16	“It’s all in the combo”
17	It starts with the bearings… Each Type 4 Store engine kit is complete with a full set of matched engine bearings including main, rod and double thrust cam bearings. The bearings in our kits are OEM quality. There are no “Coated” bearings available for kit engines as running clearances are pre-set. The use of coated bearings is limited to our Turn Key Engine program where we have full control of the engine.
18	Then add “Crank & Rods” All Type 4 Store engine kits feature our own line of Crankshafts, these are made for us by DPR Machine. DPR has provided our company with all our crankshafts since 1997 and we have yet to suffer a single crankshaft failure with their products. All Crank and Connecting Rod combinations come fully matched and balanced, ready for a final cleaning and assembly.
19	Then a shaft called a “Cam” The secret to Type 4 Power and efficiency has been and always will be in the camshaft selection. Over the we have effectively designed over six dozen camshafts for the Type 4 engine, the most effective of these are found inside our engine kit combinations. All kits feature camshaft and lifter packages that share the Aircooled Technology development pedigree.
20	And a gear to drive it… All kits are complete with camshaft drive gear. The purchaser must provide the crankshaft gear, this is typically sourced from the “core” engine that the purchaser will provide.
21	A pump for the oil…. Each Type 4 Store engine kit features a modified 1 oil pump. The Type 1 pump is a great upgrade because it moves more oil than the stock TIV pump, has great longevity and does so at a fraction of the cost. Some kits may feature “Full Flow” oiling, the same pump is used for these kits but it features modifications that make it full flow specific. Details about full flow oiling will be shared later in the presentation.
22	Then some oil system upgrades… Here are a few more components that most people would not consider part of an “Engine kit”. Pictured are a few miscellaneous parts including push rod tubes, an oil filter and a few odd pieces used for oil system upgrades.
23	Add some Cylinders and Pistons All Type 4 Store engine kits come with a full Cylinder, Piston and Ring kit. We choose Keith Black pistons and Hastings rings for our kits and couple these to new Type 4 cylinders. LN Engineering “Nickies” cylinders are standard equipment on all 2563cc and larger engine kits…
24	Then some shims Blanchard ground cylinder shims are standard equipment on all engine kits that require shims thicker than .060 These shims are used for the setting of deck height and compression ratio. Purchasers that choose our “Extensive Prep Service” will receive the shims pre calculated for the particular engine.
25	Complete Cylinder Head Assemblies The Aircooled Technology/ Type 4 Store Cylinder Head program is the most extensive in the Aircooled VW/ Porsche Industry. Several years ago we teamed up with Len Hoffman at Hoffman Auto Machine to create this program. The Cylinder Heads are the most important part of the engine configuration, they make the entire combination, incidentally they are the most expensive component in the kit, making for ½ the cost of most of our engine kits…. Nothing touches our LE series heads……..
26	Bitchin “LE” cylinder heads
27	A complete valve train Here the Valve Train components that are standard offerings in most all of our kits No detail is forgotten, down to every nut, bolt, spring, pushrod and spacer….
28	Flywheel, Clutch and Pressure plate too! New flywheel, clutch disc and pressure plates are standard equipment in all kits. We will select the proper arrangement of compatible components for your vehicle and driving style…..
29	Topped off with a gasket set, seals and spark plugs We include a gasket set, front and rear main seals, pushrod tubes and a complete engine hardware kit with each and every engine kit.
30	And a variety of sealants… Pictured are a few of our sealants that come with each engine kit. We are always working to develop new sealants and procedures to apply them the best way possible for a leak free engine. WE HATE OIL LEAKS!!!
31	"We hope these pictures and..." We hope these pictures and text have helped you to better understand what is included in every Type 4 Store engine kit. Now, we’ll go over some other “non mechanical” portions of the engine kit, because these kits are much more than just boxes of parts…
32	How about support??? We are dedicated to support… We know that the only way a novice can be successful at the task of engine building is to have a team of dedicated professionals behind them. Our program couples phone, email and forum support for every purchaser. Each engine kit comes with unparalleled support, we offer this support in two levels that are included in our two stages of “Prep Service. Basic Prep Service offers unlimited email and forum support, for 90 days with one hour of phone support during assembly and tuning. Extensive Prep Service includes multi-venue unlimited support through the assembly period and 6 months of follow up/ tuning support.
33	Service & Support Team As part of our Engine Kit program, you will receive direct support from those who have both developed and created your engine kit. With each kit sale support is standard and you won’t have to wait days or weeks for our team to respond to your questions and concerns. Above right is Jake Raby, Owner and Founder of Raby’s Aircooled Technology and the creator of the MassIVe product line. Jake assists with complex issues that can be encountered from time to time with kits and continually hones our engine kit program to offer more powerful, more efficient combinations that work just a little bit better than their predecessors. Bottom right is Blake Meredith, our engine kit specialist. Blake is primarily responsible for engine kit order filling, mock up assembly, balancing and shipping of engine kits. Blake is an avid Porsche 914 enthusiast and former SCCA SE Division Champion in E Production. Blake’s most notable characteristic is his versatility in the shop, or in the office.
34	Support comes in different flavors… Here we offer two different levels of support. With each kit support is included to aid in the critical aspects of assembly and tuning that the assembler will experience. We have aligned these levels of support with our “prep service” offerings for simplicity. Kits that are purchased in their standard form or with our “Basic Prep service” without our optional “Extensive prep service” come with limited email and telephone support. Details concerning each level of support that is available with the our two levels of prep service will be discussed later in this presentation. Purchasers not choosing the optional added support at the time of their order will not be offered a second opportunity after the kit order has been completed. Support is priceless
35	The Type 4 Store engine assembly Challenge That’s right, it is a challenge… Those who are determined will succeed… Those who are afraid will fail…
36	"Everyone will fill the shoes..." Everyone will fill the shoes of an engine builder, we’ll never take that away from the process… Doing that wouldn’t be fair… And it wouldn’t be real… We offer a challenge to those who wish to complete their own engine and have the pride of saying “I did that!” When the engine breathes it’s first breath you will get a chill up the spine that cannot be described… The only thing we promise you is a challenge…
37	The Process….. We have prepared a chronological timeline for you to better understand the series of events that will occur during the typical engine kit purchase. Following this timeline and the seven stages it details the engine kit purchaser will have the capability to prepare for the entire process, allowing for a much smoother transaction. Smooth transactions make for “fun projects” for all involved. Projects that have complications are avoided at all costs by our team. Preparation and organization are everything!
38	Stage I: Research This stage is where reference materials like this presentation, our forums and thorough research on all of our sites pays off. We like educated customers, because when a customer is well versed with components and procedures it makes the entire process go smoother from start to finish. Start your research on our online forum community at Aircooled Technology Online Community Use other sites like www.tunacan.net/t4 www.shoptalkforums.com and www.914world.com as well as Google searches to learn more about the type 4 engine.
39	Research stage phone consultation As part of your research stage we encourage an initial telephone chat to ensure that you have accurate information and fully understand the entire engine kit process. This phone chat does not obligate any purchaser to an engine kit purchase. We want to make you aware of “hidden” costs and the things that will be mandatory to complete your engine correctly, but may not be included in a particular kit. These telephone consultation sessions are handled personally by Jake Raby and can be set up by emailing enginekits@aircooledtechnology.com Due to our extensive workload and commitments these consultations are limited to 20 minutes in duration. Please stay on topic and to the point during the conversation and have a list of your questions made in advance, this will ensure we get all the info covered during the chat.
40	What else is needed??? Our engine kits include everything needed to make your engine a complete, longblock assembly out to the rocker arms and including the flywheel. The following sub systems are not included, but can be added to any engine kit order. Induction system Ignition system Cooling system Exhaust system As part of our support we will offer you recommendations for each of these sub systems when you desire. Tuning and manipulation recommendations for each of these is also offered, this includes timing and jetting specs, etc.
41	Stage II: Sourcing the foundation One of the first items you’ll be tasked with providing is the “Core”. The core is what will be used to base your engine from and each purchaser will need to source a core “Longblock” assembly for our program to be effective. We can assist you with locating a core. Our program will allow ANY post 1972 VW Bus, 70-76 914/4 Porsche, 1976 only 912E or VW 411/412 engine core to be used with equally favorable results, with our manipulation all Type 4 engines are modified equally. The only core engines that should be avoided are from the 1980-83 VW Vanagon. Ensure that you source a core “Long block” assembly, you will need more than just a case, so buy what you need because some simple “core” items are not included in the kits…
42	Stage III: The Order! Pictured left is a screen shot from our retail website, The Type 4 Store. This shot illustrates the point where engine kits begin, from here all it takes is a point and a click of the mouse to start your project. The wise consumer will have already completed their initial kit consultation with Jake and will have familiarized themselves with kit inclusions, kit policies and researched our forums and other reference materials mentioned within this proposal. With the click of the mouse the process begins…..
43	Order: Phone interview
44	Order: “Prep Service” Selection At the time of the order your only “option” for the kit will be the level of prep service and support that you choose. It is important that you consider that once a level of prep service is selected this can’t be changed during the process. The following pages will detail the two levels of prep work that can be chosen.
45	Basic level Prep Service This state of prep service is just an extension from our pre-2008 engine kit program that has been revised and more detailed. This level of prep service offers unlimited email and forum support, for 90 days following engine kit delivery with one hour of phone support during assembly and tuning. We throw in never ending permissions to view and post in our engine kit owners forum as well. We take the time to prep and inspect major assemblies and follow a 16 point check list during the preparation procedures with this level of “prep service”. This level of service does not include “mock up” assembly of components, deck height setting, Compression Ratio calculations or any sub assembly at all. With basic prep it is our goal to inspect components for flaws and ensure that all major interference is avoided for the purchaser including crank/rod to cam clearance, case clearance and etc. Our basic prep service also includes our intermediate level balance service standard. This sets the balance tolerance to .5 Oz/In. and includes static and dynamic balance of all rotating and reciprocating components.
46	Extensive Prep Service This level of prep service offers multi-venue unlimited support through the assembly period and 6 months of follow up/ tuning support after kit delivery. With this level of prep service we also include two hours of phone support that can be used for up to 6 months following kit delivery for both assembly and tuning. We throw in never ending permissions to view and post in our engine kit owners forum as well. This level of prep service includes a full engine mock up with all the critical dimensions set up including crank end play, deck height/compression ratio, valve train geometry and we’ll even supply your cylinder shims and pushrods cut to length! Please note that we do NOT complete any assembly these components we just do the calculations and set up work that allow you to bolt the kit together without a single specialty tool! ASSEMBLY REQUIRED! The goal of extensive prep service is to remove all guess work for the assembler and allow for a much smoother and faster assembly process. Our Extensive prep service also includes our RACE level balance service standard. This sets the balance tolerance to .2 Oz/In. and includes static and dynamic balance of all rotating and reciprocating components. Extensive prep service has been offered to assist the purchaser of the kit, the expenditure is more than worth what it offers in terms of support and pre-assembly.
47	Extensive prep service details Those that opt for the extensive prep service will benefit from the ability to assemble the engine with only simple hand tools. No special tools will be required, only a torque wrench! We complete compression ratio, valve train geometry, flywheel end play, and over two dozen more critical aspects of the engine assembly. Those who appreciate value will choose this service.
48	Order: Administrative Paperwork It seems that anything these days has paperwork to contend with and our engine kit program is no different. Our proposal must be signed, dated and included with your engine kit payment before we can start your engine kit. We require these proposals before project engagement to ensure that the purchaser is fully aware of the engine kit inclusions, policies of the Type 4 Store pertaining to kits and the fact that the only guarantee we’ll give you is the engine assembly Challenge. We don’t believe in fine print, all information is clear, bold, and to the point. Included in this proposal is a non disclosure clause- we don’t want our designs to end up in China! Samples of the engine kit proposal are available upon request for your review prior to the kit order.
49	Order: Payment Payment for all engine kits is required in full within one week of the engine kit order being placed. Engine kits are set up specifically for individual customers so they are treated as a custom item, even in their most standardized form. We do not accept credit cards as a form of payment for engine kits. All engine kit orders must be paid for with certified funds. Cashier’s check, Money Orders and Wire Transfers are all acceptable methods of payment for engine kits. Overseas payments are accepted in the form of wire transfer only. Engine kit orders are not processed until full payment has been received.
50	Receipt for payment and engine kit reference material Following the receipt of your payment we will send you a “Paid in Full” receipt for the kit and with this will come several pieces of reference material. Included will be an Engine kit assembly time line on CD Rom as well as a simple manual of text and pictures that you can study while we are completing our processes to the kit. Pictured is a sample of the reference CD and a typical engine kit owners manual.
51	Refunds, Exchanges and Returns This one is simple… All sales are final, no refunds, exchanges or returns are allowed. No exceptions….
52	Stage IV: Core Return Our kit program has been set up so a customer can complete an engine from a core that they already have in their possession. Core components are required for each kit, these components are dependant upon the kit that is purchased. A detailed list of the core items for each kit are available in the detailed web pages for each specific engine kit. Core items must be received within 14 days of the engine kit order, or a “core deposit” will be required. This core deposit is also variable per kit and ranges from 200-750.00 depending on the kit. Details of core charges are available for each kit, upon request. All core engine components must be received in serviceable condition and clean!!! Customers that do not have engine cores can still purchase our engine kits, we treat these instances on a case by case basis and have no standard charges pertaining to them. OVERSEAS CUSTOMERS MUST PAY CORE CHARGES- NO CORE RETURN WILL BE POSSIBLE DUE TO EXTENSIVE SHIPPING AND ADMIN CHALLENGES NO EXCEPTIONS (please do not ask)
53	Stage V: It’s our turn….. Now that you have paid for the kit, received the initial phone chat and returned your cores to us we will begin preparation for your kit. This process has no definite time lines and can be impacted by our schedule, difficulty of your kit and the promptness of our suppliers. Most kits will turn around in less than 6 weeks, but in extreme instances they can take 10-14 weeks to complete. A projection of turn around time can be acquired by sending us an email as this time varies greatly.
54	The Balance process… Here we believe in dynamic balance and every kit features some form of balancing procedures. We balance all rotating and reciprocating components both individually and as assemblies during the “prep” stages of the engine kit. Pictured are freshly balanced pistons as well as a rotating assembly that’s being balanced in our Multi-Bal 3000 balance machine.
55	Periodical Kit Status Updates From time to time during kit preparation, when your kit is “In Work” Blake will email the purchaser to set up a time that we can carry out another conference call. These ill usually be on Wednesdays in the mid afternoon. In this chat we will be available for a question and answer session and we’ll also bring you up to date with projected shipping dates and kit specifics. Most kit orders will be “In Work” with us long enough to experience two of these periodical updates. These updates do NOT count as engine kit support, so those that are purchasing only our basic prep work will not feature a loss of phone chat support.
56	Shipping! The shipping process is the final stage of engine kit preparation. All engine kits shipped within the Continental 48 US States have shipping and handling charges bundled into their retail cost. Shipping is carried out by Blake and Rebecca as each ensures that all kit components are packaged well and that all kits are complete to our pick sheets. We do not skimp on packing materials, each box is equally prepared for it’s voyage to a neighboring state, or around the world. All engine kits must be shipped, we do not allow kits to be picked up from our facility. International purchasers will experience additional shipping, handling and processing charges due to the extreme paper work and extra labor that goes into an overseas shipment.
57	Stage VI: The Fed Ex delivery…… We use Fed Ex Ground service for the shipping of all of our packages, including engine kits. Fed Ex has always given our company and our customers exceptional service with very few damage or loss claims. when something is lost or damaged prompt action and reimbursement has always been a characteristic that we look for in a company, Fed Ex delivers effectiveness and accepts their mistakes without question. We do not allow purchasers to arrange their own shipping, or use alternative shippers, this becomes complex and introduces a variable to our program. International customers receive shipments from BAX Global, we can offer “door to door” or “Door to airport” service for international kit shipments. Please provide a shipping address where someone will be present when packages are dropped off by Fed Ex so damage can be notated at that time.
58	Stage VII: Kit Inventory THIS MUST OCCUR WITHIN 48 HOURS FOLLOWING KIT DELIVERY! Using the shipping inventory sheets that were used by us to pack each box the purchaser must verify that all components are included in their kit and that the specified quantity is also correct. During this process please inspect each part for shipping damage. ALL claims of damage or missing kit components MUST be received by our engine kit department within 48 hours of the delivery!!! Issues that arise after this time, or occur due to neglect on the purchaser’s behalf could result in components not being replaced promptly or “free” We deal with losses and damage claims promptly as long as our policies are followed, reimbursement for lost or damaged goods is up to the discretion of Fed Ex and not under our control-
59	Transaction completion With our processes completed and all kit components safe and sound within the confines of your garage, after a successful shipping experience the transaction is now completed. You can now prepare for the next step and the final phone conversation with our kit specialists before your adventure will begin. You can follow the engine kit assembly time line (included with all 2008 kits) found on the engine kit reference CD from this stage forward to assist with the chain of events that will occur through the assembly process.
60	The Challenge Begins Are you ready?????
61	2008 Engine Kit Offerings Please click one of the selections below to learn all details about our specific engine program offerings for various applications and displacements. We have segregated these offerings for simplicity, you can view the pages as web pages by clicking top links, or as a power point presentation by clicking the bottom most links. Note that if viewing as web pages you MUST have Internet Explorer 7. Link to Porsche 914/912E engine kit offering specifics Link to ALL VW engine kit offering specifics
62	Credits This has been a Raby Productions Presentation Compiled by Jake Raby With assistance from the Aircooled Technology Team Produced on location at Aircooled Heaven All content copyright 1997-2008 Raby Enterprises Inc.