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EJ Series Engine into a Buggy

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Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#187454
Well there I was with a clean looking shed... seems I need to get me a project .... oops there is a buggy that needs and EJ motor up its ass.




Yep she fits like a glove ...



Sump won't hang that low for long .....
Brad
Why copy when you can own an original ?
Meyers Manx Australia

MickH Hairy Gutted Sloth

3,389 posts · joined Sep 2003 ·

#187455
Here we go again...........
tssnq.com.au

Andy42 Insano Dub Head

709 posts · joined Mar 2003 ·

#187494
AHHHH water cooled the answer to everything :thumb But the question is why are you taking pics and not working on it instead 😀 And when is the production line on the sumps starting ya must have several ready to do now :thumb
.

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#187519
hehe EXAMS.... I go walking every 2 hrs to clear my head and just happened to have a Cameras ....

Production line - soon very very soon..... We currently plan on having the following items for sale to make this conversion much much easier and quicker:
- Shortened Sump Kit - This will be an exchange kit and includes a shortened sump approx 75mm less than stock but same capacity and a matching pickup
- Rear engine mount sub frame - this is a bolt on unit and give your horns all the support you need.
- Exhaust Systems - both stainless and mild steel. Kit includes gaskets, cat, exhaust and mounting hardware, ready to bolt on.
- Throttle Body Inverter - thsi lets you fit the EJ into bugs and buses, it turns the throttle body 160 degrees and allow clearnance on the body , fitment of pod filter and lets the stock VW throttle cable be used.
- Front mounter Radiator Kit - Include new alloy radiator, thermo setup with shroud

As well as these bolt on items custom units are also availible as far as radiators and exhausts go. Engineer approval of EJ Conversions using our kits is also availible for approx $80 if requierd and all items come with instructions.

Please note all kits listed above are sold complete with all bolts and brakets to fit. Complete EJ Mounting kist will also be availible which will include EVERTHING you need to take your EJ and bolt it into your VW. EJ's can also be supplied at competitive prices with warranties.

Yep we have set on a direction and are no folloing it pretty hard. This buggy with be finished pretty soon and will be the test bed of all our products....
Brad
Why copy when you can own an original ?
Meyers Manx Australia

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 ·

#187571
you keep saying "WE" and "OUR".........................who is "we" and "our"? surely you don't mean your wife...................she should have disowned you years ago !


Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#187590
hehe no you are correct I don't.... I mean me and my business associates. All will be revealed shortly enough... just putting the finishing touches on the Business side of things .....
Brad
Why copy when you can own an original ?
Meyers Manx Australia

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 ·

#187594
Buggybrad...........................................Bill Gates !


Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#187610
mmm not ... hopefully our products will have less bugs and if they do have bugs then I expect our customers would be less accepting than his of them.
Brad
Why copy when you can own an original ?
Meyers Manx Australia

lexm Commited Dubber

57 posts · joined Apr 2004 ·

#187931
Please note that advertisements, chain letters, pyramid schemes, and solicitations are inappropriate on this forum.

This looks dangerously close to an advertisement.......🙂
Buggy Brad wrote:Production line - soon very very soon..... We currently plan on having the following items for sale to make this conversion much much easier and quicker:
- Shortened Sump Kit - This will be an exchange kit and includes a shortened sump approx 75mm less than stock but same capacity and a matching pickup
- Rear engine mount sub frame - this is a bolt on unit and give your horns all the support you need.
- Exhaust Systems - both stainless and mild steel. Kit includes gaskets, cat, exhaust and mounting hardware, ready to bolt on.
- Throttle Body Inverter - thsi lets you fit the EJ into bugs and buses, it turns the throttle body 160 degrees and allow clearnance on the body , fitment of pod filter and lets the stock VW throttle cable be used.
- Front mounter Radiator Kit - Include new alloy radiator, thermo setup with shroud

As well as these bolt on items custom units are also availible as far as radiators and exhausts go. Engineer approval of EJ Conversions using our kits is also availible for approx $80 if requierd and all items come with instructions.

Please note all kits listed above are sold complete with all bolts and brakets to fit. Complete EJ Mounting kist will also be availible which will include EVERTHING you need to take your EJ and bolt it into your VW. EJ's can also be supplied at competitive prices with warranties.

Yep we have set on a direction and are no folloing it pretty hard. This buggy with be finished pretty soon and will be the test bed of all our products....


[Edited on 16-6-2004 by lexm]

Doug Sweetman Nil Bastardo Carborundum

2,128 posts · joined Sep 2002 ·

#187940
Chilll out, Brad is a moderator so I'm guessing he is pretty aware of the rules, seeing as he helped set them up........

Sounds great Brad ! The buggy looks like a fun little toy too.

When are you ever going to get back onto the Mega Manx though, with all these little distractions ?

Jenny Officially Full-On Dubber

352 posts · joined Jun 2003 ·

#187944
Wow Brad, let us know when you have your 'demo' sump pan and engine sub frame made up. I may be interested if it will fit the Eureka and the price is right. Went for a spin in an EA71 powered Eureka last night and it was prety quick, so an EJ20 powered one is going to be great!

MikeM Buggy Head

1,429 posts · joined Aug 2003 ·

#187964
lexm wrote:This looks dangerously close to an advertisement.......🙂
Good thing you put a smilie on the end. Hate for anyone to take you seriously. Although it appears Doug did 🙂

The rules seem to state no advertising, but we all advertise stuff to sell it in the "Buying and Selling" forum.

In the rules for the buy and sell sectio it states:
For our commercial traders (ie those whose primary business is the sale of goods or services):

The Commonwealth Trade Practices Act and your state's Sale of Goods act (or similar) apply here, just as if someone bought from you across the counter

You must put in a price of the goods you have for sale, along with indicative shipping costs.

If you do a lot of business here, please consider sponsoring the forum to offset our operating costs. It's cheap.
There seems to be a bit of contradiction between these rules and the board rules. ie. Board rules say no advertising. But advertising is the whole point of the Buy and Sell section.

I guess Brad counts as a forum sponsor since he arranges web space etc for the forum and does allot of behind the scenes work. So as a forum Sponsor the company currently known as "we" 🙂 can list their services, I guess.

Anyway, enough off topic discussion for me...

I'm interested in the EJ conversion gear, especially the throttle body inverter, exhaust, and shirt sump.

Keep us all informed of progress Brad. And let us know when the company currently known as "we" is ready for business.


[Edited on 17-6-2004 by MikeM]


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Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#188102
"For our commercial traders (ie those whose primary business is the sale of goods or services)"

Man anyone who thinks I do this as my primary business really is dreaming in a BIG way .......

Although I dunno if it is an add as nothing is actually availible ...... not that it matter as I am guessing you are just trying to get a response......... now back to the shed .....
Brad
Why copy when you can own an original ?
Meyers Manx Australia

tonyg Seriously Crusin Dubber

174 posts · joined Oct 2003 ·

#188115
Brad and DJ mech hmmm? just fishing
they took me away haha, hope the medication works

pete wood 23 Windows of Awesome

6,828 posts · joined Jan 2004 ·

#188174
Hey brad,
Had a look at your new project. Thumbs up, except for one thing....

the ej motor is missing 2 cams, LOL 😀

P.s Curious to see what the sump kit will look like
"stoopid is stronger than axles"
http://drivingnotpolishing.blogspot.com.au/

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#188363
Clayton at DJ informs me he isn't goint to do them anymore as he has to much work on.

Also I work for myself and would be a very bad employee as the Boss would always be wrong ..hehe

The sumps will look about 75 mm shorter and larger .........
Brad
Why copy when you can own an original ?
Meyers Manx Australia

seagull Compulsive Aussie Vee Dubber

4,979 posts · joined Dec 2003 ·

#188452
Brad I have asked chris to post a big photo for me on the ej22 I am doing now ,you can see the header tank* fixed to the where the air con would be the gold bit you can see near the ally plate .

As the radator is at the front and low ,i have fitted a blead pipe to the top of the radator as to allow the air to run back to the header tank ,this is were you would fill the H2o .

any way I hope this gives some one some ideas or help
my radator is 600mm long x 300mm and a 3 row core .
seagull

:beer
Looking for that special lady : PM me for coffee & cake

Desert Moose Cut Cut Cut

2,098 posts · joined Mar 2004 ·

#188454
seagull wrote:Brad I have asked chris to post a big photo for me on the ej22 I am doing now ,you can see the header tank* fixed to the where the air con would be the gold bit you can see near the ally plate .

As the radator is at the front and low ,i have fitted a blead pipe to the top of the radator as to allow the air to run back to the header tank ,this is were you would fill the H2o .

any way I hope this gives some one some ideas or help
my radator is 600mm long x 300mm and a 3 row core .
seagull

:beer
Its still not good but here it is . I will work on it later for you seagull. (this is as close as I get to workin' on a suby..lol)

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seagull Compulsive Aussie Vee Dubber

4,979 posts · joined Dec 2003 ·

#188456
thanks Moose I told you , in the end you would come to the other side
and who has a subaru in there shed chris .
Looking for that special lady : PM me for coffee & cake

Desert Moose Cut Cut Cut

2,098 posts · joined Mar 2004 ·

#188457
brad I sent it 2 u as an email

Chris

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#188489
Thank for the pic, BUT you can't actually see the tank in the photo ..
Brad
Why copy when you can own an original ?
Meyers Manx Australia

seagull Compulsive Aussie Vee Dubber

4,979 posts · joined Dec 2003 ·

#188940
I get another phot brad and email it to you , seagull
Looking for that special lady : PM me for coffee & cake

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#189474
Thanks,
well the prototype sumps are done, fitting will occur next week. We took 85mm off her and didn't loose ANY oil capacity from the standard one ....

Very cool ...... :party
Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#191163
Well the stock EJ sump sits at about 160mm from teh base of teh case and hold 6L of oil. The new and improved EJ Sump sits about 85mm from the bottom of the case and holds 6L. This means that we can now put the EJ series into the Buggy and loose 15mm of ground clearance over a type 4 and about 35mm ground clearance over a type 1.

With the installation of a Kombi Transmission Kit from Custom Offroad the engine can easily be angles slightly and the sump design allows for this.

The sump retains factory engine mounts and exhaust flanges. Stock Dipstick is also used but will need to be re-marked.

Yep now the ground clearance issue is sorted must get back to those twin muffler and single cat exhaust designs.....



Brad
Why copy when you can own an original ?
Meyers Manx Australia

MikeM Buggy Head

1,429 posts · joined Aug 2003 ·

#191257
Looks good.

In the subaru SAE paper for the EJ engine it mentions that special care was put into the shape of the oil tray and the windage tray. Hopefully the shortened sumps don't lead to oil aeration problems.

Here is the SAE paper.
http://www.surrealmirage.com/subaru/files/SAE_boxer.pdf

Attached is the particular section I'm referring to (p11). Hopefully you will have no issues with your design as you are keeping the Windage tray.

I'm not trying to be negative or have a go you, it's just a concern I have with the shortening of the sumps. The SAE implies a signifigant amount of R&D was spend on the sump and now were're hacking it up to get it under a buggy. 😠

Time will tell I guess once there are a few cars running around with shortened sumps on them.

I hope my concerns are unjustified and I hope your design works well. That way I can get you to do one for me 🙂

[Edited on 23-6-2004 by MikeM]

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Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#191304
hehe funny that you mention that as I actually read that paper before we made it. I spoke to the Subaru Guru's and showed them what we have made. They beleive it will work fine.

In the sump we have modified we have allowed for the aeration and retained the two top baffles, crank splash shield and stock oil level. After talking to the Subaru Engineers I was happy that the areas solved by Subaru where done so with these additions.

The depth of the EJ Sump assists with Surge, a problem we have solved with baffleing. Due to the design of the sump and the EJ Case the oil pickup can not run dry until the vehicle hits about 45 degrees or over for a prolonged period. If this happens you are in the poo anyway and I suggest you switch of you engine and crawl out of the buggy ..

We have also allowed for the engine being in the buggy backwards, unlike the stock EJ Sump which is designed to go in the front of the vehicle.

Oh well time will tell 😎

I must say I think it was very stupid of Subaru not to take buggies into consideration when they were builing this baby......
Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 ·

#191326
That is a good question Mike , thanks for asking 😀

Ok, it was probably badly written ... what I mean is that on a stock dip stick you would expect the oil to sit in the middle of the marks. Now teh max oil level is the same as before but teh minimu will be slightly higher. What we suggest is that when you firts fill her up with the factory quantity of oil you mark your stick so you know exactly where a full ej sits on your engine / sump. That way you can better judge your particular engine.

The modified sump 3.6L mark is exactly the same as the stock sump for 3.6L mark and after that it is stock so the capacity is the same, does that make sense ?
Brad
Why copy when you can own an original ?
Meyers Manx Australia