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 DubCrazy
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| posted on September 12th, 2011 at 07:12 AM |
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been buzy while i was away young man, u still on the right time frame for warrick?? cant wait to see and see how she goes. nice job...
steff........
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 matberry
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| posted on September 12th, 2011 at 08:18 AM |
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Good work Smileyman. I'm glad people get to see the effort that is necessary for this type of work, and what most workshops need to address.
Don't forget these little additions, important in my opinion
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
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AJPerkins
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| posted on September 12th, 2011 at 09:37 PM |
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What a read mate! A great thread. You have more talent in your little finger than I will ever have! 
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Smiley
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| posted on September 12th, 2011 at 10:43 PM |
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| Quote: | Originally
posted by DubCrazy
been buzy while i was away young man, u still on the right time frame for warrick?? cant wait to see and see how she goes. nice job...
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I certainly hope so! I'll being pushing her if I have to but she'll be there!! How was the trip away? You'll have to take the weekend off and drive
your little beast down to Warwick too!
| Quote: | Originally
posted by matberry
Good work Smileyman. I'm glad people get to see the effort that is necessary for this type of work, and what most workshops need to address.
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You aren't wrong! I probably have nearly 10 hours in the tinware alone!
| Quote: | Originally
posted by matberry
Don't forget these little additions, important in my opinion
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Are these on the underside of the head?? And what is the second picture of? I can't quite make it out properly.
| Quote: | Originally
posted by AJPerkins
What a read mate! A great thread. You have more talent in your little finger than I will ever have!
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Thanks for the kind words 
Smiley 
If you said I was a Volkswagen man, you'd be right.
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matberry
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| posted on September 13th, 2011 at 08:35 AM |
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Yes, Smiley, top pic is underside of head, second pic is looking into barrel cover fitted, the little air vane near the fan shroud mounting screw
isn't fitted to new tinware. They make stacking the product less effective. lol
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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bajachris88
A.k.a.: Chris Leete
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| posted on September 13th, 2011 at 12:57 PM |
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update update update  !!!
your so close Daniel!
You gotta have this ready for Warrick...
I've got a rwc inspection booked in tomorrow morning so we can cruise in early october 
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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Smiley
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| posted on September 13th, 2011 at 07:28 PM |
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| Quote: | Originally
posted by matberry
Yes, Smiley, top pic is underside of head, second pic is looking into barrel cover fitted, the little air vane near the fan shroud mounting screw
isn't fitted to new tinware. They make stacking the product less effective. lol
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No worries. I'll make a set up at my next convenience
And I don't need to worry about the upper cylinder covers, I'm using some stock ones that I've fixed up. But it's something I'll keep in mind if
I have to use new ones at some stage.
Thanks again for your help Matt, I look forward to meeting you at Warwick and seeing your Baja up close in the flesh.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 07:32 PM |
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| Quote: | Originally
posted by bajachris88
update update update !!!
your so close Daniel!
You gotta have this ready for Warrick...
I've got a rwc inspection booked in tomorrow morning so we can cruise in early october
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So close yet so far!
Now that yours is done you can pop up and help me get mine finished off!!
Just make sure yours is nice and running sweet and I'll see you at Warwick.
I'm off to do more welding!
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 09:42 PM |
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I painted up the backing plates and fan and assembled the alternator. So I could make sure that the fanhousing was sitting in the right place when it
bolted down.
When sitting down it still had a slight gap underneath it. I ground a little more off the bottom of the fanhousing where it was sitting down on the
block. After this it sits down nicely and the fanhousing bolts up well.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 09:47 PM |
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Last thing on the tinware list was the oil cooler dump vent.
The new ones that came with my fanhousing were complete rubbish. Not even worthy of the recycling bin in my opinion. The fit is horrible and doesn't
bolt up to the fanhousing nicely at all. Not to mention the fact that the two halves of the vent don't even fit together in the slightest!!
I went for a scrounge through the stash up top and dug out a nice pair of factory items. The fit is far superior.
Here they are bolted onto the fanhousing.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 09:54 PM |
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One issue I ran into was how to hold the bottom half of the vent steady, as I am not running the front breast plate on the engine that would normally
support this piece.
So I bent the inside lip down a little further.
And borrowed some metal from this useless heap of junk.
Smiley
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Smiley
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| posted on September 13th, 2011 at 09:56 PM |
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A weld here and a weld there.
And we have a neat little support tab that sits onto the upper cylinder cover.
Then all I did was drill a hole and weld a nut on the inside of the tinware.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 10:03 PM |
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Ok. Now onto what I did tonight.
I finally managed to get my new support tubes bent up right. I got them back yesterday and they weren't bent as far as I wanted so dad was kind
enough to take them back down today and get them bent to where I wanted.
Blue is new, black is the old setup.
I made a cardboard template so I could work out what length I needed to cut it to. It's so much easier to mock up with card and cut with scissors
when lying under the car.
Once everything was the right length I cut the clamps off the old bars, cleaned them up and welded them to the new ones.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 10:16 PM |
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Here is the tube sitting in place with magnets.
It clears the trailing arm at full droop (which is what the car is currently sitting at). These tubes should give me heaps of strength in my rear
barwork (which is good if I want to tow a trailer), give me somewhere to mount a skid plate to and help stiffen up the framehorns some more.
And all welded. It unbolts and comes off easy. But the plan is to not have to remove it ever, until I want to upgrade my down travel of course
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 13th, 2011 at 10:21 PM |
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Last thing I did tonight was start to get the cage to fit back up again.
Trimmed the tubes to the correct length and bolted the under mounts in place.
I just need to make some plates up and weld them on, then drill some holes and weld nuts on the back.
Still plenty to do!! More soon.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 15th, 2011 at 10:48 PM |
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All of the tinware except the fanhousing has now been painted.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 15th, 2011 at 10:49 PM |
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Finished making the lower rear cage mounts.
I still need to round and smooth the plates off.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 15th, 2011 at 10:53 PM |
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I took the rear crossmember off and trimmed the ends to length and smoothed them off.
Then it was cleaned and straight to the 'paint booth' 
Along with the transaxle mount.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 15th, 2011 at 11:10 PM |
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I fitted the Under pulley tinware, then the sand-sealed pulley.
And all of the cylinder cover tinware has been fitted for the final time! I got some pretty allen button headed stainless bolts for it. As well as
spring washers to stop them vibrating loose. Everything went on without any dramas, it'd want to given the hours I spent making the tinware fit!!
I've also fitted the long reach plugs that my old man picked up for me today.
I have new CV boots and rear flexible brake hoses coming from Mick Motors. And the local brake shop is making me up new hard lines for on the diagonal
arms.
A friend of mine from work and fellow VW enthusiast has kindly rebuilt the CVs and axles for the car (just waiting on the boots)
I had a good long chat to Mr Penrose yesterday on the cam break in and engine run in procedure. Also discussed carby jetting, service intervals among
other things. Lots more infor for my tiny brain to try and take in 
I still have a list as long as my arm of stuff that needs to be completed, but I feel like I'm starting to knock down the brunt of it. I now have
less that 2 weeks before I'll be on the road to Warwick (driving down the Thursday night). And I need to get the engine started ASAP and driving so I
can run it in and get some kms on it before driving +2000km down to Warwick. I want at least 1000k on the car before we go so I can give it a major
service and valve set before we leave.
Well that's me for tonight, lets do it all again tomorrow shall we?
Smiley
If you said I was a Volkswagen man, you'd be right.
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bajachris88
A.k.a.: Chris Leete
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| posted on September 15th, 2011 at 11:28 PM |
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yay! gonna burn rubber all the way down to warrick
I haven't got the underpulley tinwear fitted, is that something i should really get on top of?
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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Smiley
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| posted on September 15th, 2011 at 11:33 PM |
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| Quote: | Originally
posted by bajachris88
yay! gonna burn rubber all the way down to warrick
I haven't got the underpulley tinwear fitted, is that something i should really get on top of?
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If you're running a stock pulley then it's a must.
A lot of dirt/sand/etc gets flicked onto the back of the pulley and can get drawn into the engine by the spiral groove that keeps the oil in. Because
I have a sand sealed pulley it's not really as important but I put it on for a little bit of extra protection. Plus it also helps support your
cylinder cover tinware and oil breather tubes.
Smiley
If you said I was a Volkswagen man, you'd be right.
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bajachris88
A.k.a.: Chris Leete
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| posted on September 15th, 2011 at 11:35 PM |
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ah i c! i got a sand seal, thats no worries (slip in style, no machining).
i did notice though that the upper tinwear was a little 'loose' fitting. will fish through the spares and see if i still got it lol.
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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Smiley
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| posted on September 15th, 2011 at 11:38 PM |
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| Quote: | Originally
posted by bajachris88
ah i c! i got a sand seal, thats no worries (slip in style, no machining).
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I'm running the same style. I really like the degreed pulley that came with the kit too. Makes setting the timing a breeze.
Smiley
If you said I was a Volkswagen man, you'd be right.
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bajachris88
A.k.a.: Chris Leete
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| posted on September 15th, 2011 at 11:42 PM |
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You do have some pretty flash hardware
you'll have to give me a demonstation when you come on down to warrick. not sure if i'm game to ask what the bill was lol. None the less worth it
, many years of trouble free motoring are ahead of ya.
I like your bar work on the rear, that'll surely keep the stress outta those rear forks. Now you just need a boat to tow with ya to Fraser
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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Smiley
A.k.a.: Daniel Stephens
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| posted on September 15th, 2011 at 11:47 PM |
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| Quote: | Originally
posted by bajachris88
You do have some pretty flash hardware
you'll have to give me a demonstation when you come on down to warrick. not sure if i'm game to ask what the bill was lol. None the less worth it
, many years of trouble free motoring are ahead of ya.
I like your bar work on the rear, that'll surely keep the stress outta those rear forks. Now you just need a boat to tow with ya to Fraser
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No worries. We'll have to go for a cruise after racing stops on Saturday or something.
And I don't need a boat, It's for pulling out bogged 4WDs
I'm also planning on adding a 3 bar Kafer kit if Craig ever messages me back.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 19th, 2011 at 09:34 PM |
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Unfortunately I was away this weekend from Friday till Sunday at a Rover activity in Emerald. Then when I got back I was sick as a dog all of last
night 
I managed to get a little bit more done this afternoon when I was feeling better.
I sanded back the fanhousing on Friday before I left and my dad was kind enough to paint it for me while I was away.
Sanded back.
And primed then painted, and here it is fitted to the engine with the alternator. I had to reshim the fan a little because it was rubbing once
everything was bolted down.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 19th, 2011 at 09:48 PM |
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New clutch and accelerator cables fitted (isn't this an annoying job), new hardlines on the diagonal arms and new flexible brake hoses.
Then I fitted the gearbox and framehorn cross member.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 19th, 2011 at 09:58 PM |
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Then I fitted up the manifolds, carbs and linkage kit.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 19th, 2011 at 10:11 PM |
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This is the stock mount that came with my oil filter housing. It mounts off the exhaust studs. I don't mind the location, I'm just a little worried
about it hanging too low and copping rocks from the LHS rear wheel. What do you people think?? I think I'll just run with it for now and put a foam
stubby cooler over it.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 19th, 2011 at 10:19 PM |
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Then I got to work on modifying my exhaust.
First think I found was you couldn't even do the nuts down properly due to the welds being in the way. So a little tickle with the grinder and a
smooth off with the file sorted that issue.
I cut the ends of the exhaust tubes down to try and minimize the height of the system.
Then I cut the collector off the muffler.
It'll be welded on like this.
That's all I got down this afternoon. Still plenty of little jobs to be done.
I'm picking up my CVs and axles tomorrow, and need to drill and tap the Type 3 dipstick plate for my temp sender. But if all goes to plan I'd like
to start the engine on Wednesday. Not long now till Warwick!!!
Smiley
If you said I was a Volkswagen man, you'd be right.
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