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 nils
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| posted on May 11th, 2012 at 02:22 PM |
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You're a man of many talents smiley
Quit calling rust patina
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Smiley
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| posted on May 11th, 2012 at 04:31 PM |
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| Quote: | Originally
posted by nils
You're a man of many talents smiley
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Thanks mate. That means a lot coming from you. I've seen the work that has gone into your car.
I have a quick question for you. When you put the hanging pedal in you car for the accelerator, do you need to get that approved and blue plated?
I'm considering the possibility of underslung pedals for mine.
Smiley 
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 12th, 2012 at 06:13 PM |
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Well seeing as none of you gave me any ideas I opted to chop the whole bottom off the airbox and rotate by 180° and plastic weld it all back
together.
I did it with the element in and top clipped in place to try and keep it all square and stop it pulling itself out of shape from the heat.
All welded in place 
I also picked up some new rubber mounts for the box on Friday. Plan is to throw the engine back into the car tomorrow and fab up a frame to support
the box in place where I want it.
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 May 17th, 2012 at 10:17 PM |
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Well I've made some good progress since the last post.
Have changed the way to box is being mounted. When I sat it in place with the 3 rubber mounts bolted to the bottom None of them lined up nicely with
anything to mount to.
So I'm now running two mounts on the fanhousing and one off the top of the throttle linkage pivot.
I borrowed a nutsert gun and put some threads in the shroud for the mounts. These are a nifty little tool, they are basically a pop rivet with a
thread down the middle of them. I might even look into buying myself a kit.
Then I had somewhere to mount two of the mounts for the box.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 17th, 2012 at 10:22 PM |
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The third central mount is bolted onto the frame for my carby linkage pivot.
And with the airbox base in place. You can see everything has plenty of clearance 
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 17th, 2012 at 10:27 PM |
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I had some super duper spacers rings made up to adapt the Commodore inlet flanges onto the Kadrons. You can also see the cross bar that has been
welded into the tube.
Spacer goes here.
And then this fits over the top. And bolts down using the factory Kadron aircleaner mount threads.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 17th, 2012 at 10:32 PM |
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Look what showed up in the mail today.
At least 5hp per silicon bend I think!
They go here like this.
And the alloy tube will be trimmed to length and fit in the gap like so.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 17th, 2012 at 10:40 PM |
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I'm going to have to pull the engine and cut off the stock decklid hinge mounts.
They are in the way.
And worse on this side. Nothing the grinder can't fix.
Aside from that the clearance is very good. Doesn't rub on hit on anything. I've always wondered what the hump in the engine scoop of the Baja kit
is for, it's so you can fit an airbox!!
Thanks for reading, more very soon.
Smiley
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BlueV2
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| posted on May 18th, 2012 at 09:46 AM |
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Smiley, why do you have a spark plug in your exhaust system ?
Nice airbox by the way 
Sharpbuilt V2, EJ25, Subaru 5 Speed, Falcon rear discs, Heater & A/C, Rack Steering
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Smiley
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| posted on May 18th, 2012 at 01:39 PM |
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| Quote: | Originally
posted by BlueV2
Smiley, why do you have a spark plug in your exhaust system ?
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That's where my O2 sensor goes. I had it out when I took the engine down to the Gold Coast and we rebuilt it. And I knew that we were going to run it
up, so I plugged the hole. The large spark plug is the same thread size as an O2 sensor.
Smiley
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BlueV2
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| posted on May 18th, 2012 at 02:17 PM |
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Huh, I thought you were using it to light the afterburner !! lol
Sharpbuilt V2, EJ25, Subaru 5 Speed, Falcon rear discs, Heater & A/C, Rack Steering
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Smiley
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| posted on May 19th, 2012 at 09:55 AM |
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| Quote: | Originally
posted by BlueV2
Huh, I thought you were using it to light the afterburner !! lol
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Hahahaha Yeah! Shoot a nice plume of flame out onto the ground.
She's not running that rich!!
Smiley
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Smiley
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| posted on May 19th, 2012 at 10:00 AM |
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So I got stuck in last night and finished off my airbox setup.
I needed to make room on the firewall area where the hoses looped around.
So I got stuck in and trimmed 90% of the drip rail off. As well as the decklid hinge mounts and prop srping
mouhttp://forums.aussieveedubbers.com/post.php?action=reply&fid=25&tid=80275nt.
Smiley
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Smiley
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| posted on May 19th, 2012 at 10:05 AM |
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They I trimmed the alloy tubes down to length.
A very easy way to mark tubes evenly and straight it to put a hose clamp on and tighten it up. Then use this as a guide to make your cut. This is a
very good method of getting straight cut when you are cutting a front beam to fit adjusters.
It wasn't long before I had this 
Looking ready to ruin some 4WDs day now 
Smiley
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SebastienPeek
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| posted on May 19th, 2012 at 10:12 AM |
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Looks the goods Smiley!
Can't wait to see it back in Alyce.
Are you expecting to notice any difference whatsoever?
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Smiley
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| posted on May 19th, 2012 at 10:16 AM |
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It wasn't long before I had it fitted up to see if everything cleared. I'm happy to report that to clears the firewall completely!! Only thing I had
to do was slide the coil an inch or two lower in it's clamp to clear the LHS pipe.
And it all clears the engine scoop with plenty of room to spare.
As far as servicing goes, all I have to do is loosen the two hose clamps onto the carbies, undo the clips on the airbox and it wiggles out easily!
I have fitted a K&N oilable filter element to the airbox, and am looking to run a prefilter or two on the inlet to the airbox before I take it
offroad.
I'm sure that this setup should work a great number of times better than the old setup, and prevent me prematurely wearing out the rings and the
bores again. All I have to do now is finish connecting the engine up and refit the rear barwork. Then I can start running her in.
I'm interested to see if the induction noise will be different, hopefully it's a little quieter.
Smiley
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Smiley
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| posted on May 19th, 2012 at 10:44 AM |
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| Quote: | Originally
posted by SebastienPeek
Looks the goods Smiley!
Can't wait to see it back in Alyce.
Are you expecting to notice any difference whatsoever?
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I expecting to notice a lot less oil consumption, and an engine life of more than 6 months/25000km.
Hoping the induction noise might be a little less and the filter is a lot more easy to service now too. And it's easier to fit a prefilter.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on May 28th, 2012 at 10:34 PM |
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Just a quick update.
I've been driving the car to work and around, basically as much as possible to run the new engine bits in.
I've done over 1000kms in the last week since I started driving her again.
Fuel economy is a little worst than it was, I've averaged between 13.2 and 13.5L per 100km. But all the tanks have been very close together in this
range which I think is a good thing.
The A/F ratio gauge indicates that she's running rich throughout the rev range. So I'm sure with a few adjustments I can get a little more economy
out of her. Getting down into the 11s would be great, we'll see how things go.
I'm currently working on fitting a digital speedo (with a twist) to the car so I'll put some posts up of that when I get it all sorted and ready to
go in.
Smiley
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big_ash
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| posted on May 28th, 2012 at 11:17 PM |
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Looks the goods!
Vw crazy  |
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kaiisons
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| posted on May 29th, 2012 at 12:03 PM |
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hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
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Joel
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| posted on May 29th, 2012 at 12:19 PM |
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Ready to start on mine?
it's still in the "I haven't worked out how the hell I'm gonna do this" stage at the moment.
You make plastic welding look so easy.
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ian.mezz
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| posted on May 29th, 2012 at 01:01 PM |
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| Quote: | Originally
posted by kaiisons
hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
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looks like there is a hole in the side of the lower half.???
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1303Steve
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| posted on May 29th, 2012 at 02:45 PM |
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| Quote: | I'm considering the possibility of underslung pedals for mine.
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Hi
Love your work.
Do you know why Dr. Porsche designed the pedals that way as in bottom hinged?
Have look at how your ankle joint works when pushing on the brake or clutch pedal then imagine how it would work with underslung pedal, you will see
that underslung pedals cause the ankle to try to bend the wrong way.
Larry Perkins amongst other V8 racers set up bottom hinged pedals to reduce fatigue on the ankle joint, we will probably never have this problem but I
thought I would point it out.
Steve
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Smiley
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| posted on May 29th, 2012 at 08:07 PM |
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| Quote: | Originally
posted by kaiisons
hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
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As Ian has suggested there is a hole in the forward facing edge of the bottom half of the airbox. I faces towards the fanhousing. There is plenty
enough gap there to allow enough airflow. The hole is the front of the box is 55x105mm which works out to 5775 square mm.
I filled the car up again this morning and am happy to report that the last tank I got 12.4L per 100km. Which is a great improvement, I guess
everything is starting to bed in properly. I wouldn't say that it's running rich due to lack of airflow, just that the mixture screws need adjusting
slightly.
| Quote: | Originally
posted by Joel
Ready to start on mine?
it's still in the "I haven't worked out how the hell I'm gonna do this" stage at the moment.
You make plastic welding look so easy.
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Plastic welding is easy!!! Send it up my way and I'll be happy to glue the stuff together for you
I've been using my gas soldering iron, the flame is adjustable which helps regulate the tip heat. When plastic welding sometimes you want to throw a
fair bit of heat in to get the puddle flowing and other times you want low heat to prevent you from blowing holes in it.
This is my one that I've been using. It comes with a variety of tips so I've picked the one that suits plastic welding the best.
The tip I'm using has a 'pie slice' cross section. I've found it the best one in the set for welding. You can use the sharp edge to cut through
the plastic, the large flat sides are good for smoothing and the rounded back is great for getting into concave hollows and tight corners.
I hope this info helps you out.
| Quote: | Originally
posted by 1303Steve
| Quote: | I'm considering
the possibility of underslung pedals for mine.
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Hi
Love your work.
Do you know why Dr. Porsche designed the pedals that way as in bottom hinged?
Have look at how your ankle joint works when pushing on the brake or clutch pedal then imagine how it would work with underslung pedal, you will see
that underslung pedals cause the ankle to try to bend the wrong way.
Larry Perkins amongst other V8 racers set up bottom hinged pedals to reduce fatigue on the ankle joint, we will probably never have this problem but I
thought I would point it out.
Steve
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You make an interesting point Steve. Something that I would not have thought about. I figured that because most newer vehicles have underslung pedals
that is would be the superior option. I was more wanting to get the pivots etc up out of the crap as my footwell often gets full of sand and mud etc,
despite how often I clean it all the moving parts cop a lot of contamination. I figured that moving the mounts up onto the firewall would reduce the
crap getting into the moving parts and stop them wearing out as quickly. I also planned to upgrade to a hydraulic clutch at the same time.
Thank you for you input, I guess it's more info to process before I decide to make the swap or not 
Thanks to everyone else for their comments. There's no point updating a build diary unless people are going to read it and leave some feedback
Smiley
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Smiley
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| posted on May 31st, 2012 at 07:22 PM |
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Have got her down to a best of 12.32L/100km when I filled her up last night.
Due for a valve set when she's cold early in the morning before I go to work, and a service tomorrow after work when she's hot
Smiley
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1303Steve
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| posted on May 31st, 2012 at 07:43 PM |
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Hi Smiley
I have regularly clean my pedal area as well, I can see your reasoning to go underslung
I'm not sure if you already commented or not, does the filter make any difference to induction noise?
Steve
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 matberry
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| posted on May 31st, 2012 at 07:51 PM |
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Good one Smiley.
I'm with Steve on the pedals, pet hate converting beetles to hung pedals
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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Smiley
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| posted on May 31st, 2012 at 08:37 PM |
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| Quote: | Originally
posted by 1303Steve
I'm not sure if you already commented or not, does the filter make any difference to induction noise?
Steve
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It's not of any noticeable difference.
Maybe a tiny bit quieter. I can't really tell over the exhaust.
I really need to get some more sound proofing into this car, it's very loud for a daily driver. I'll probably be deaf soon. Worth it though, getting
to drive my aircooled Volksie and watch all the fools with their 'new' cars.
Smiley
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Smiley
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| posted on May 31st, 2012 at 08:41 PM |
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| Quote: | Originally
posted by matberry
Good one Smiley.
I'm with Steve on the pedals, pet hate converting beetles to hung pedals
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Is it for the above mentioned reason?
Or something else you don't like about the conversion?
Smiley
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matberry
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| posted on May 31st, 2012 at 09:34 PM |
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I've always been most comfortable with floor pivot, I also always considered it to be more 'correct' for our ankle movement and felt under hung are
purely a function of front engine engineering. Never realised Dr Porsche considered it a must for the same reason.....
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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