before I start, I want to thank you all for the useful information I got from this forum and all the other build-threads.
I've been reading your post for a long time and I think now it's time to tell my own story...
It all started almost 3 years ago when I decided to create something you can't buy at any car dealer. I always like the concept of an old car with a lot of power nobody would expect...
Although many people (especially in this forum) have done such a project before, it's a totally different story when you try to do it yourself.
Today, we are almost done. I already did some short test drives, but we still have issues with the ECU and the engine is not running properly above 2.500 RPM.
However, here are the specs:
1303 super beetle from 1972
Subaru EJ25 SOHC from a 2000 Legacy
Adapter plate and exhaust system from LMB Technik
custom engine mount
Porsche 914 5-speed gearbox
228mm clutch from a VW T3 bus
Porsche 944 S2 brakes front and rear
Porsche 944 rear arms, driveshafts and front wheel hubs
Remmel Motorsports coil-over suspension front and rear
Cup-style struts
Heigo roll cage
So stay tuned and enjoy (hopefully)...
I'm sorry for the bad image quality, most of the pictures were taken with my smart phone...
Chr_ ·
When we started disassembling the car, we found alot more rust than we expected ... but that's the same story with every project, isn't it?
Chr_ ·
After the main welding work was done, we split the car in two...
Chr_ ·
We had to replace one of the side panels and used the opportunity to fit a slotted front-end for the radiator...
After that, the chassis got sand blasted and repainted in black.
Chr_ ·
This gave us time to gather some parts like the gearbox, brakes, driveshafts, adapter plate and so on...
When we got the chassis back, the fun part of the project began..
Chr_ ·
We started to mount the gearbox, the rear arms, coil-overs and the struts.
We also test-fitted the engine with a reversed intake manifold.
Chr_ ·
To fit the Porsche 944 handbrake mechanism to the beetle handbrake cables, we had to build some custom parts... looks somewhat sweet...
After that, we were able to mount the brakes and the exhaust system.
Rear-end was almost completed.
karmann141 ·
Great stuff- more please 😎
1303Steve ·
great read more please
Chr_ ·
After that it was time to get the chassis back on its wheels (at least the rear ones) and test-fit the body.
It didn't quite fit at that time, so we had to cut away some inner structure of the rear end and most of that piece of metal that is between the engine and the gearbox.
The cat agreed...
Chr_ ·
Some work on the radiator.
It's from an Alfa Romeo 33. The frame is custom-made.
I think Joel proposed it in one of his youtube videos. It fits perfectly and works like a charm, thanks for that!
Chr_ ·
Some more custom Subi-related stuff.
We fitted the original Subaru fuel pump into the fuel tank of our beetle.
It is a very tight fit, but the spot seems to be really good since the inlet of the fuel pump should be very close to the lowest point of the tank.
Chr_ ·
In the meantime, I prepared the front axle and brakes.
Check out my high-end sand-blasting ... yeah.... rain barrel and cardboard...
Chr_ ·
Mounted everything to the car...
Chr_ ·
Then it was time to the car back on its own wheels.
So now it's about 1.5 years since the start of the project.
These pictures were taken in February 2014.
The rims are Porsche Cup 7x16 with an offset of 55 front and 9x16 (70 offset) rear.
benny_acko ·
So good!Keep it coming...
kombi_kid ·
very nice build! question about the manifold rotation did you just keep the injector wires to where they originally would of been or did you leave the loom attached and rotate around?
cheers
rhys
retroresto ·
Nice work guy, Keep up the pics coming, I have a soft spot for 1303's!
Joel ·
Chr_ wrote:Some work on the radiator.
It's from an Alfa Romeo 33. The frame is custom-made.
I think Joel proposed it in one of his youtube videos. It fits perfectly and works like a charm, thanks for that!
Glad it worked out for you, they fit like they are meant to be there.
Mine served me well even with an A/C condenser infront through many aussie summers, it's been replaced by a racing aluminium radiator now with a bash plate for protection this time.
My cars seem to be roadkill magnets unfortunately.
Doug Sweetman ·
Doubt there are many 1303's that see as many miles a yours too Joel.
Outstanding project !
Chr_ ·
kombi_kid wrote:very nice build! question about the manifold rotation did you just keep the injector wires to where they originally would of been or did you leave the loom attached and rotate around?
cheers
rhys
Hey,
the loom remained in its original position, so injector wires, spark plug wires and everything is connected to the same cylinders as before.
I had to create a small sheet-metal adaptor for the iginition box to rotate it back 180 degrees so I could mount it in its original position on the rotated intake.
The connection of all thoses hoses is another problem. Since I also rotated the coolant manifold, some hoses did fit as before, some other had to be replaced with longer versions and routed across the manifold.
On the upside, I did not have to cut my firewall and the throttle cable can be mounted straight forward without any complex re-routing...
SebastienPeek ·
The amount of want and desire to build something similar is back.
Chr_ ·
Long time no beetle...
Sorry for delay, but here we go again:
We spent a lot of time to make everything fit.
Some minor and major body work, some additional holes here and there...
We had to do some work on the fenders, as well.
Front fenders are stock metal fenders, rear fenders are GRP +4cm on each side.
Chr_ ·
Some more pictures on that topic...
Finally the car was ready to prepare it for paint.
Chr_ ·
Some intermediate stuff:
Wrapped the exhaust and made custom engine mounts.
The engine mounts attach to the original holes of the rear bumper mount. The other side gets screwed to some custom brackets, holding the exhaust...
Chr_ ·
After a few weeks of boredom, the car was finally ready for paint...
Chr_ ·
That's it for now...
For those of you wondering why I named this thread "Death by chocolate...", here is a little teaser.
Stay tuned...
karmann141 ·
Love your work - eagerly waiting the next installment. Thanks for the chocolate teaser.
What part of the world are you in by the way?
Joel ·
That header is a work of art.
Is that a Porsche colour?
Wheeler dealers restored a 928 that was a very similar colour a few years back
Aussie Dubbin ·
I'd be wrapped with those headers😀
Chr_ ·
Hey guys,
I'm glad you like my header, but I have to admit, that just bought it and wrapped it with some heat protection tape...
The credit for actually making these things goes to Reiner Kuhn and his company "LMB Technik".
They also make adapter plates and other stuff for VW Subaru conversions.
Here is a pic of the complete exhaust system...
The color btw. is just some random dark brown chocolate style color I chose because I really liked it. I don't know if it belongs to any specific car or bike or something.
karmann141 ·
ANY UPDATES ??? THANKS
1cut808 ·
Hell Yeah.... This is a sweet as build!
Frapps ·
Keep up the good work! Looks great!
adlbeetle66 ·
Want to see more here 👍
Chr_ ·
Hey guys,
it's time for some updates!
sorry for the delay...
So when we got the car back from the paint shop, we started assembling everything.
Chr_ ·
more pics...
Chr_ ·
we started with the interior and built a wooden cover for the battery and ecu.
Chr_ ·
Almost done...
Chr_ ·
installed the final seats and completed the engine bay
Chr_ ·
This is it...
Three and a half years from a white rusty 1303S with 50 horsepower to a completely restored chocolate brown EJ25 powered 1303.
I hope you like it.
helbus ·
Great! Everything is a great job.
Flintstones ·
Nice 👍
karmann141 ·
Excellent job - Ferdinand would be very happy with how you've evolved his humble creation.
Willie ·
Beautiful
nbturbo ·
You have done a fantastic job with your car-it's a credit to you, very well done.
time8theuniverse ·
Looks great. Nice work.
HerbieBoy82 ·
Awesome !!!
joesbuell ·
Superb build!
Chr_ ·
Some nice pics from end of October
Chr_ ·
last one...
Squalo ·
What a beautiful (and functional) car! Full credit to you.
oldskoolguy ·
Wow, that's really nice. Well done 👍👍
Yogie ·
I have to say that is a great colour and you have done a fantastic job. Well done.