Stealth Kombi

fatdadis · 2011-04-02T05:56:13+00:00

Starting a topic to document my travels as a Kombi enthusiast...time to Share.....will start with lots of Pics. (Just learning to resize in photoshop...). Been into serious mods from about 2001. This is a FUN car - not a historically valuable 1960 splitty that should be left stock. I've modified lots of stuff, and done things a few times to get it right - so if I can help a newbie get his/her bombi on the road with less pain / cash outlay...then I'll feel good. Why modify? .....FUN.....and, lets face it, when the subie engine hits full boost it is rather cool (you keep up with “annoying little cars” easily....and can shock everybody if you want to give it a bit of juice...not my style, but good to have the power when necessary, particularly when loaded up). Add proper air conditioning (and heating), better fuel efficiency, electronic ignition, quad cam, fuel injection, TURBO,...GENUWINE factory replacement engine parts.....and you have my motivation to go to a subie.....and you gotta love the rumble sound it makes. Being a big car, the donk doesn’t overpower you - and I've never felt out of control (but, please, lower the car if you want sporty cornering - rear sway bar and "moderately" lower profile tyres help heaps). The stock Kombi brakes go fine, just pay attention to the rear drum adjustment on a regular basis, so they are at optimum. Anyway, specs: EJ20T (very early, but similar spec to WRX. ie 147kW/256Nm....but with a really short exhaust, so more power to wheels than if it was in a front engined car). Got as front cut....you will need all the bits and pieces. Didn’t use radiator....wanted a reasonably nice front view of Bombi....so many horror stories with bad rad. Placement...Get front cut with gearbox, if you are starting out – and follow my progress with the reversed Subaru gearbox. Water intercooler......gets air through tasteful side scoop. Tranny....stock 2lt kombi....with 0.7 4th gear - NOT happy with this in terms of suitability with donk..ie. turbo engine needs totally different 'box to make most of its power band (and not a 40 year old VW 4 speed). Having gone to the trouble to wack in a modern donk, many will / have been disappointed with the gearbox.....and I'm not going to take the compromise any more - so i'm going to wack in a perfectly suited reversed subie tranny, see Todd at www.subarugears.com for details.....build will take place in May/June, hopefully - will provide many pics. Radiator.....up front, where it belongs. I don't run ANY fans...even in stinking hot conditions....even when stuck in traffic idling.....even when I'm driving a little sporty....the temp NEVER goes over 90 d/cel. Rad is custom, so I can make it a nice shape suitable for covering with fibreglass spoiler. Obviously not as clean as stock look, but I'm happy that its probably as good as a radiator will look on a Kombi - and it does give it a little "attitude". System has 2 bleed points and rad cap/overflow bottle is in engine bay. Used copper lines - no probs (done about 30K in current setup)....but does need 12 monthly flush. Runs stock water pump / thermostat, no probs with circulating (the now 12lt) of coolant. Other stuff: Fuel tank (stock) under back seat - fits easy, but needs to be in an enclosed space....working on an aluminium box for this, as a speak. Gear leaver and brake between seats....took some thought / playing - but now good as gold...and I can run much shorter gearstick, so quicker gear changes, in a more comfortable position. Hiace large capacity air conditioner mounted above rear cargo area.....will be going by next summer. Aftermarket under dash heater/demister on its way from US soon. Skull side marker indicators (why not). Custom LED rear indicators.....front harley bullet indicators - so the "Boxy" mid '70s indicator look is gone from front and back......front air intake grill gone too – quarter vents make up for this.....air con will help even further. Air con will have custom roof ducting (like airplanes) to keep peeps chilled. Towbar in engine bay - just tow ball sticking out back - which you can do with a subie donk being so short.....also have bike rack attachment permanently attached...all covered by painted aluminium plate. Limo style partition, to front, so kids can fight in peace - and also (more importantly) so that the air con only has to cool the front cabin when I'm not ferrying family. Similar partition (in progress) behind rear seats, so air con won't need to cool space above engine....which does get warm. Will add lots of insulation to help air con, as well... Deleted top rear air intakes - looks smoother - replaced with "rocket engine" holes in rear engine lid, to get heat out of engine bay. Not to many people’s taste, and I agree it is a little funky/brave.....but key word is FUN. Recessed rear reversing lights, in bumper. Chrome 16 inch wheels (Speedy brand – come as blank wheels, and they are drilled to suit....have correct offset)....lower profile tyres at…

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 2 Apr 2011, 7:15 pm

#833765

bump remodel

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:17 pm

#833766

custom manifold

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:18 pm

#833767

downpipe

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:19 pm

#833768

up pipe

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:20 pm

#833769

sump and manifold left h.side

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:20 pm

#833770

manifold rhs

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:21 pm

#833771

old setup with sump / manifold sticking out back

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:22 pm

#833772

oil fill cap....noice

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:23 pm

#833773

engine bay layout....older version

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:24 pm

#833774

new bay layout

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:25 pm

#833775

dash....work in progress

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:25 pm

#833776

petrol tank reposition

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64 posts · joined Jan 2010 · 2 Apr 2011, 7:26 pm

#833777

DONE posting for now......

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 2 Apr 2011, 8:04 pm

#833785

helbus wrote:It is really good to show so many aspects of the build to help others. It helps to answer so many questions when you do it yourself. I did our bus quite a while ago now, and I am in the fortunate position that I modify and build cars for a living. I was able to do the whole job in one go, and pass engineering first time. It is a great feeling when that piece of legal paper is in your hands and it is all done.

How did you go with your engineers report?

Was a while ago....2004 maybe....been playing/ changing suff ever since. Engineer looked at rear seatbelt mounts, engine mount rigidity, "tubing" bolt holes through chasis rail...stuff like that - which I fixed easily. Didn't care about engine power upgrade, brakes, etc...so all went through quick. Made sure I got in touch with him early in the piece to save disapointment. Not sure of current laws. Insurance was trickier....shannons to the rescue...cheers.

ElusiveStranger Officially Full-On Dubber

330 posts · joined May 2006 · 3 Apr 2011, 10:05 am

#833877

Liking this bulid bud!

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 3 Apr 2011, 2:04 pm

#833915

SEE YOUTUBE TOUR of engine bay:

CLICK FOR TOUR

helbus Administrator Mad fabricator, paint and body

7,386 posts · joined Sep 2002 · 3 Apr 2011, 6:40 pm

#833956

fatdadis wrote:Was a while ago....2004 maybe....been playing/ changing suff ever since. Engineer looked at rear seatbelt mounts, engine mount rigidity, "tubing" bolt holes through chasis rail...stuff like that - which I fixed easily. Didn't care about engine power upgrade, brakes, etc...so all went through quick. Made sure I got in touch with him early in the piece to save disapointment. Not sure of current laws. Insurance was trickier....shannons to the rescue...cheers.

The only companies I found would insure our bus with the engineers report were Shannons and LSV.

LSV actually wanted a copy of the report.

EJ22 into Bay Microbus - Finished project build thread- click on this spot here for info

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 3 Apr 2011, 8:53 pm

#833983

Will be following along with the 5sp swap, Todds setup is my next big step.

One thing though, honestly running no radiator fans is going to turn around and bite you in arse eventually.
I know what you're saying, if I don't run my A/C mine dont run till I've stopped moving for atleast 5mins.
The saving grace is nearly triple the stock coolant capacity and such a long metal pipe run does a lot of heat exchanging but there are times when that simply isn't enough.

Coming back from Brisbane abit over 12 months ago there was a major car prang at Coomera and it took me over an hour to get about 3kms as traffic was at a standstill.

at an average speed of 0.00004km/h my fans were cycling regularly, no where near as much as the cars around me but still running every 5 or so mins.

Every mechanic will tell you there is no way your's wouldnt boil over in this instance.
Best way to kill the headgaskets, especially an early RS motor.

By the way you can add 4 photos per post, just keep clicking the ( Add Attachement) button on the side.

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 4 Apr 2011, 12:07 pm

#834026

Joel wrote:Will be following along with the 5sp swap, Todds setup is my next big step.

One thing though, honestly running no radiator fans is going to turn around and bite you in arse eventually.
I know what you're saying, if I don't run my A/C mine dont run till I've stopped moving for atleast 5mins.
The saving grace is nearly triple the stock coolant capacity and such a long metal pipe run does a lot of heat exchanging but there are times when that simply isn't enough.

Coming back from Brisbane abit over 12 months ago there was a major car prang at Coomera and it took me over an hour to get about 3kms as traffic was at a standstill.

at an average speed of 0.00004km/h my fans were cycling regularly, no where near as much as the cars around me but still running every 5 or so mins.

Every mechanic will tell you there is no way your's wouldnt boil over in this instance.
Best way to kill the headgaskets, especially an early RS motor.

By the way you can add 4 photos per post, just keep clicking the ( Add Attachement) button on the side.

Hi fellow dubber.......

Can't wait for the gearbox swap......this, along with sorting the air con, will transform the bus into what every vw owner wishes for.

Take your point about the radiator fans....I only stumbled opon the fact I didn't need them because a fuse blew (when I was running fans) and I was away from civilization.
Drove car home (120K) on a hot day, loaded up and through some traffic jams....and good as gold.
This was 2005ish. Driven 60k + km's since, and no matter what....never goes above 90 - and had a few situations like you have mentioned. Combination of big crossflow rad., 12lt of coolant and long sections of piping from front to back, does the trick...and has stood the test of time.
Maybe I'll pretend that I scientifically worked out the cooling issue.....when people ask.....cheers

What? multiple pictures per post !!! excellent....will try

pete wood 23 Windows of Awesome

6,828 posts · joined Jan 2004 · 4 Apr 2011, 4:05 pm

#834046

very different. initially i was a bit iffy with that front bar, but you put it together well and the driving lights make it too. really nice bus.

p.s. must be freakin hot in matt black though!

"stoopid is stronger than axles"
http://drivingnotpolishing.blogspot.com.au/

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 4 Apr 2011, 6:39 pm

#834080

pete wood wrote:very different. initially i was a bit iffy with that front bar, but you put it together well and the driving lights make it too. really nice bus.

p.s. must be freakin hot in matt black though!

Cheers........Not as clean looking as a stock bombi, but their is a little bit of nastyness with the front spoiler - looks a little sporty. Paint is clearcoated, just not rubbed back and buffed (tried matt but too hard to live with). Going to put lots of insulation / heat shielding inside and get air con going before next summer...can't wait to get this done, and crank up the cool air!!!!

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 4 Apr 2011, 6:49 pm

#834086

fatdadis wrote:Take your point about the radiator fans....I only stumbled opon the fact I didn't need them because a fuse blew (when I was running fans) and I was away from civilization.
Drove car home (120K) on a hot day, loaded up and through some traffic jams....and good as gold.
This was 2005ish. Driven 60k + km's since, and no matter what....never goes above 90 - and had a few situations like you have mentioned. Combination of big crossflow rad., 12lt of coolant and long sections of piping from front to back, does the trick...and has stood the test of time.
Maybe I'll pretend that I scientifically worked out the cooling issue.....when people ask.....cheers

What? multiple pictures per post !!! excellent....will try

I found the same thing with my A/C condenser fan.
on the open road my A/C works fine with no condenser fan, the diode for it burned out and i stopped at home to open the shed door when I jumped back in it was getting hot inside, when I checked the fan wasnt running, natural air flow when on the move was enough but soon as I stopped it just wasnt condensing the gas with no airflow through the condenser.

It doesn't take much in the way of fans, I've only got a pair 9" thermos on the rad and it can manage on just one but it takes alot longer.

fatdadis Commited Dubber

64 posts · joined Jan 2010 · 4 Apr 2011, 7:46 pm

#834094

other stuff....

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64 posts · joined Jan 2010 · 4 Apr 2011, 7:47 pm

#834095

skull markers......red eyes light up with indicator....

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64 posts · joined Jan 2010 · 4 Apr 2011, 7:48 pm

#834096

front rad bleed screw under grommet

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64 posts · joined Jan 2010 · 4 Apr 2011, 7:51 pm

#834098

moved position.......nice and close to driver.....handbake with extended handle for good leverage.....shorter shifter nice and quick....

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64 posts · joined Jan 2010 · 4 Apr 2011, 7:54 pm

#834099

custom housing (steel) for subie stalks......multi speed intermittent wipers....way cool

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64 posts · joined Jan 2010 · 4 Apr 2011, 7:56 pm

#834100

Hiace large capacity a/c unit......ducting to come - each passenger gets roof mounted air nozzle...yeah baby....

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64 posts · joined Jan 2010 · 8 Apr 2011, 8:49 pm

#834717

have had faint petrol smell for a while......couldn't find cause......finally decided to redo fuel delivery.....so binned stock tank....

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64 posts · joined Jan 2010 · 8 Apr 2011, 8:49 pm

#834718

new version

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