just went back through a few of the pages to page one. Jeez, this has been a hard slog. Well done. Are you planning on a little bit of cage for some trackdays or will it only be a street car?
that last pic of the front end looks absolutely mint, cant wait to see that same angle with guards & the lid on it 😀
so for another similar sunny day ill look in about.... 10yrs? 😂
nice work rich, jealous of your progress as usual 🥲
Volkswagen Drivers Club of Queensland - member 🙂
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
It will be a street car. I'm sure I'll take it down the strip or round a track at some point before they ban me for being too fast without a cage 🙅 In my head I have thought out how I'd put in some mounts on the chassis for a removable cage if it's really required, one of the benefits of having a strong chassis with decent framework 🙂
Last concentrated burst of activity before I start my new job tomorrow at Jaguar Land Rover.
I made up a couple of aluminium plates to stop the torsion bars sliding inside, also a small bracket for the 2 new fuel pipes (5/16" kinifer) which ended up clashing with the body so I'll have to redo that!
You can just make out the chargecooler pipes coming out through a new plate at the front of the chassis, I also ran new front and rear brake lines. Instead of the usual cheap rubber body gaskets, I bought a long length of foam gasket and made my own VW style one, didn't take too long, hole punching it as I went to line up with the body mount holes and then glued any ends together with sikaflex.
Body on! I also mounted the bonnet as it was taking up far too much space in my workshop.
The rear frame will get stripped/painted, but that's for another time. it makes a very good carry handle when lifting the body about...
I can see that it's going to look HOT!!👍👍
Cheers
D
Rear valance panel needed extending at the top to meet what was left of the body neatly. It bolts in place at the top and is then clamped between the body and wings down each side.
Plenty of ground clearance!
Body panels all 'thrown' on for the moment as my wife was sick of them spread out everywhere, lol!
I'm happy with how it's all sitting...
Id be happy too if mine looked like that.
71-BEETLE-SEDAN wrote:Id be happy too if mine looked like that.
I would be beyond happy if mine looked that good.
I want to see the look on the face of the first focus/cavelier/SRI/GTI owner that takes you on at the lights! 😂
If anybody else had a feeling that the doors didn't look quite right in the previous pictures I was having the same thoughts! In the end after repainting and then re-clearing they have come out right. I also wet-sanded and machine polished the whole car so I can start refitting brightwork and other fittings...
Much better!
Door windows in, it was like doing a 3D jigsaw puzzle that would only go together in a particular sequence!
I've put in all the door hinge screw not too and am really please with how the doors line up with the rear quarter panels, the swage line is perfect. I just need to pack up the rear body spacer a small amount to get the door gap parallel.
there's something very 'hotwheels' about those rims. very cool. looks great mate. I think this one might be a keeper eh?
That's the plan this time but you never know! Might try playing with engines for a while using this car as the rolling testbed.. A 2.5 CDB or H6 turbo'd is appealing right now and the gearbox should cope no problem!
2.5 CBD?
what's that?
turbo H6 would be very cool... and tyre destruction on a stick 👍
CDB=closed deck block, stronger starting point for boost 😬 You can get a CDB re-sleeved up to 2.5 rather than going for the weaker semi-closed 2.5 sti block...
🤓
in the words of Arnie, "DO IT, DO IT NOW!!!"
I've been doing loads of little jobs, mainly refurbishing parts before refitting them.
Definitely getting there! All glass now in after spending a small fortune on various rubber seals which were too far gone to re-use.
The G50 was a real pain to detail! Porsche use a really thick type of wax and liberally spray it on all over the underside. A 10mm wire brush was the best thing to get it out in the end. Lots of degreasers and finally etched and painted in alloy wheel silver should keep it looking much better and cleaner in the long run... You can also see the steel spacer under the front mount.
The engine's turn on the stand for some detailing... I'm probably going to go with black wrinckle paint for the alloy bits (cam covers and intake manifold).
Engine stripped back to a bare longblock and painted in POR engine enamel..
Cam covers were stripped back and treated to some VHT black wrinkle paint.
Coming back together, new cambelt hiding under there too...
Lots of now redundant bosses were cut off and smoothed to give a cleaner look and the manifold also painted in wrinkle. This is how it looks straight away...
....and after a couple of hours!
Engine just about ready to go back in the car...
I decided to shorten the sump but only by an inch or so as that will just about bring it level with the exhaust manifold and oil filter and maximise ground clearance.
Cut up and new component parts. I filled in the slope at the front part to regain lost capacity and it turned out near enough identical to the original volume. I cut slots at the top and bottom of the additional triangular section so the old sloped wall acts like a baffle.
All welded up, just needs a clean and like of paint, then to shorten the pick-up tube. Note the drain plug is at the low point...
Looking and thinking about it now I might weld on some strengthening ribs on the bottom level wiht the drain plug to add some strength...
how did you weld it, MIG?
Yes, had to chase down a couple of tiny leaks but not too bad. I'll be brazing the pick-up pipe to guarantee no pin holes...
In the end I welded on some strengthening ribs which also serve as a flat bottom and stop the drain point getting damaged. Note that the old sump drain 'bulge' has already been flattened on the old sump so the gain is better than it looks here...
Stock pick-up pipe
shortened to suit the new sump. I also had to shorten the support piece. Normal clearance to the bottom is 16mm but I reduced this to both gain useful capacity and it was easier to just shorten the vertical section and braze it back together, I ended up with 9mm to the bottom. Apparently subaru rally cars are modified to only 6mm...
Finally fitted, the actual oil part of the sump is level with the bottom of the oil filter and I didn't want that to be the lowest point. All in I have gained about an inch ground clearance.
your windage tray and motor look nice and clean. that's a good motor there.
What an Awsome F*#king build
Congrats ,Engine came up sweet
While the header was off and in pieces I took the opportunity to get the die grinder out and do some match porting, apparently this is good for a fair few bhp!
All painted in high temp paint and mocked up on the engine to check ground clearance. The aim was to make sure the oil filter wasn't going to be the lowest point and this looks about right to me...
The original up-pipe lagging was savable so just painted but the rest will be wrapped and repainted.
Manifolds wrapped. I used the stainless ties that came with the wrap but found stainless MIG wire worked better, fitted every few inches.
8m of 2" wrap went into the manifold and another 10m for the downpipe! The wrap was soaked in water first as it later shrinks to a tighter fit as it dries out. Due to the low temperatures at the moment it was taking forever to dry out so I improvised and left the hot air gun blowing down the inside of the exhaust and it worked great!
Additional support made up to support the muffler end of the exhaust. I managed to scrounge enough stainless bar to make a bracket on the exhaust and made up the support using a mini style exhaust rubber mount.
All fitted up. Note I also painted the wrap to stop it absorbing water, oil etc later on..
Quick check to confirm the muffler is not the lowest part..
Looking good, Rich
Hi
Looks great Rich, are you running a cat or is that in the up pipe?
Steve
looks sweet👍
not long now🙂
Cheers
D
No cat on this Steve..
Next job is to finish off a few bits and pieces in/around the engine bay before putting the engine and trans back in, it's amazing how much workshop space they use up!
I can't wait to hear this thing 👍
Corrado VR6 turbo
Karmann Ghia EJ20
wow.. nice work
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