Well time to start a new thread. I got the body back from the panel beaters yesterday, and have begun the massive task of carefully fitting it out again.
I'll be doing daily postings (if I have time) to show the progress of the re-assembly. Thus far today I've fitted out my first single piece window door, fitted the dash, (connected up the steering) fitted the new steering wheel, fitted gas luggage compartment struts, new handle, and stainless fingernail scuff plates.
DAM IT LOOKS GOOD!
Chrome and polished stainless next to silver just looks SO HOT!!!
So, let the drooling begin... 馃檪
2443TT 路
another picture
[Edited on 23-7-2004 by iswinkels]
2443TT 路
Another picture
[Edited on 23-7-2004 by iswinkels]
2443TT 路
The last one for today!
nbturbo 路
"AWESOME" Is that a VW silver?
2443TT 路
Porsche Arctic Silver. 6 lt of base coat, 6 litres of clear. under the guards and the entire underside is black.
sean68 路
Quick question
What brand is the speedo......can't see because it is blurred
I'm looking for one of those but i thought autometer only came in mph
your bugs coming along nicely...... well done
[Edited on 23-7-2004 by sean68]
Stanley 路
Is this the red one in your signature line being rebuilt?
Must admit i'm partial to silver cars.
Nice work, lookin' good
Che Castro 路
wow that looks schmick!
2443TT 路
Yep it the rebuild of the red beast. The red shell is at the Cairns dump. There was too much major structrial rust... aka the new shell.
The speedo is an autometer. Their entire speedo range is available in metric numbers. The same order code as the imperial numbers except with a M after the number.
Last night I finished putting together the passenger side door, bolting on the guards and fitting the beading trim and fitting more rubber seals. Hopefully i'll get a lot more done today. No new pictures yet...
Cheers,
Dasdubber 路
That is looking fantastic Ian, this is really the enjoyable part of the project whereby everything is coming together!
Keep it up!
GL1972 路
Ian,
I bet it's like xmas every time you look at it. Looks great.
2443TT 路
Here's the latest round of pictures. I've fitted bumpers, windscreen wiper motor, more wiring, engine bay sound proofing, engine bay seals, and taillights. No problems so far, except for the usual stuff you encounter when using "EPMI" products... Than being 50% of the stuff fits (after modification that is)... As for the Briz fully polished billet bumpers the quality is awesome!
Pictures of those will be posted on the weekend when I bolt on the front bumpers. (don't want to risk scratching them while still assembling them.
The carbon fiber engine bay goes together tonight!
Cheers,
2443TT 路
Sharpbuilt fan 911 fan shroud fan mount with fan and strap attached, and a picture of a coffee cup a friend made for me... 馃檪
barls 路
looks smooth mate love that dash, mine will be started and up and running before the end of the year
2443TT 路
Tail lights, engine sealing rubbers installed. Love the smooth rear apron... no exhaust cutouts.
Che Castro 路
Mmm looks great! love the look of a smooth apron. I got a smooth apron too on mine
2443TT 路
At last here comes the engine bay... soon to be followed by concealed wiring, manifolds, injectors throttle bodies... and if I have time, the custom new water to air intercooler!
Cheers,
Ian.
2443TT 路
One more...
Robo 路
Nice work.
Rob...馃槑
2443TT 路
HI everyone, thanks for the feedback and suggestions.
Well today was quite productive. I still haven't started on the wiring as planed as I got side tracked with the engine bay instead.
I also got the oil lines and fuel lines sorted out as well as the oil cooler installed. Ever tried jaming a 12"x12" cooler in under the parcel shelf.... well 4 hours later I managed to get it it and all connected. Under the parcel shelf on the other side will be a small 210mmx110mm cooler that will be used for the standalone WATER cooling system for the turbo.
I'm quite happy with how the new fuel line placement worked out. I've made enough room to fit a water to air converted S14 intercooler, and it will still look decent and tidy. I'm thinking of using careera style dual front radiators for the water to air intercooler system. Should be affective having the coolers right out in the air streem infront of the car, plus it will look pretty cool too!
I'm finishing the engine bay tidy up tomorrow, and then starting on the wiring.
Cheers,
Ian.
[Edited on 31-7-2004 by iswinkels]
2443TT 路
Another pic.
2443TT 路
Last pic for today.
2443TT 路
Sunday has been quite productive. The engine is now completely re-assembled (excluding ECU wiring), and most of the front end of the car is now wired.
Here's the latest pics.
Cheers,
2443TT 路
And a pic of the front wiring panel.
I've re-worked the wiring system this time (again) and have documented it thouragly. I'll post the circuit diagrams for the car after I've finished putting it all together. Its a fairly straight forward design, where I run a 300 Amp cable to the front of the car, and then use 4 relay's and 2 x 7 way fuse blocks to distribute power.
None of the factory VW switches caries any real heavy currents. High/low beam, ignition switch, headlight switch etc all drive fuse protected relay sub circuits to provide peak power to the device being turned on.
Anyway... here's the pic... So much for getting it drivable for monday. The wiring isn't finished and I couldn't source a fan belt of the correct size. Anyway, perhaps by next monday.
Cheers,
65busser 路
Just awesome!!!!
2443TT 路
Well here's the latest updates. Wiring is virtuallt complete, just the interior light, alarm and number plate light to wire up.
All the glass is in, and the mirrors on. The engine has been test run and the new oil lines didn't leak. 馃檪
Just the decklid, rear number plate and rear bumper to go now. Should be driving it on the road by wednesday.
So... here's the latest pics...
Cheers,
2443TT 路
Another pic.
2443TT 路
another pic...
barls 路
nice mate very smooth id love to see that on the road
2443TT 路
last pic...
nbturbo 路
Did you take any pics of your throttle bodies and injectors mounted?Would be keen to see some if you did.
2443TT 路
Here's a pic of the throttle bodies. I thought the method that CB performance used to hold the injectors in kind of sucked, so I cam up with this idea.
The fuel rails have a threaded hole between the injectors. There is an allen head bolt that is locktighted into the rail that pulls the injector rail down to an aluminium block.
The aluminium block is about 6mm thick and has a hole in each end. One end for the allen head bolt to pull the fuel rail downwards, holding in the injectors. The other end bolts onto the bottom of the throttle body to manifold bolt for the number 3 cylinder.
The hardest part (not realy difficult at all), was to shave a little off the bottom of the manifold flange next to the bolt so as to get the correct height for holding the injectors in place.
It works perfectly, and is much more stable than CB's method that used the same aluminium block to hold the fuel rail in from the top.
I hope this helps.
Cheers,
2443TT 路
Well here's the latest pics. The car is drivable at last! I've driven it to work for the past two days, which is a good thing becasue I was getting sick of the push bike...
The car still needs a rear bumper, and some more custom work to get the carbon fiber engine lid to fit.
These photo's were taken late in the afternoon, not realy an ideal time of the day to take pictures as it gave the silver a kind of yellow tinge from some angles.
Well enough talk... here's the pictures.
Cheers,
2443TT 路
Another pic.
2443TT 路
Last one for the moment...
nbturbo 路
Thanks-I can't quite work out whats going on there from the pic.A very close up shot.It all looks like it is very compact and neat though.Do you have any from different angles?
Midlife crisis 路
very sweet drive
pyr0 路
damn thats smooth turned out great 馃槑
2443TT 路
Here's another attempt for an explanation of the injector rail system I'm using... excuse my lack of artistic tallent....
Thanks for the feedback everyone. I'll hopefully have some of the rear end of the car with the CF engine lid by monday. I am SO looking forward to having it finished...
Cheers,
[Edited on 12-8-2004 by iswinkels]
nbturbo 路
Thanks-I think I'm onto it now.It's a good looking set up.I havn't seen any aftermarket systems with the injectors in the manifold-they are normally in the base of the throttle bodies.Are the throttle bodies from CB as well.What size are they and how many $$.Do they have provision for a TPS.
2443TT 路
Yep the injectors are normally in the manifolds on the CB manifolds as well as the original port injected vw's. There are kits such as one that Turbo City released that is throttle body injection, but i'd guess that was done more out of cost saving rather than from a performance angle. It allowed them to cheaply adapt hardware from other cars.
The throttle bodies do have bosses that can be drilled to allow fitment of another 4 injectors, to allow 8 injectors to be run. I "might" go this way myself and run another set of 4 370cc injectors, instead of upgrading to 550 cc injectors, as my EFI computer supports injector staging. This allows me the benefit of small injectors for low end economy, as well as the necessary flow for big HP.
The throttle bodies i'm using from CB are 48mm, which is pretty massive, but now i've got my linkage setup properly the throttle control is light and not overly sensative (controlable at low speed).
I hope this all makes sense.
Cheers,
gayanne 路
Looks good Iswinkels,whos doing the carbon fibre work for you?and do you have a picture of the decklid. JVLRacing
2443TT 路
I got one from Luke... can't remember his last name. Its very good quality but sits low in the middle. Fortunatly I have an original W steel decklid that I am making up some carbon fiber ribs in. These will then be removed from the steelie, and glued into the CF lid. That will pull it in to shape.
I'll post some pictures of that process too shortly.
Cheers,
BiX 路
that looks very sweet, love all the wiring being exposed and stuff. I want that car, so where do you live again?
gayanne 路
iswinkels wrote:I got one from Luke... can't remember his last name. Its very good quality but sits low in the middle. Fortunatly I have an original W steel decklid that I am making up some carbon fiber ribs in. These will then be removed from the steelie, and glued into the CF lid. That will pull it in to shape.
I'll post some pictures of that process too shortly.
thanks for that, they are my carbon fibre bootlids that i had made from my mould which i supplied to luke its the same on my racecar.Looking forward to seeing it on .JVLRacing
[Edited on 13-8-2004 by gayanne]
2443TT 路
And here goes a little carbon fiber...
As I mentioned earlier I have a carbon fiber W engine lid, but it doesn't quite fit. The curve of the lid doesn't accurately follow the contour of the car.
My solution has been to make a rib out of carbon fiber/fiberglass to pull the engine lid back into shape. I am fortunate to have an original steel W decklid to make up the rib in. Then all that will remain is shaping the rib and glueing it into the CF engine lid... In theory...
Here's a pic of the cf rib being glued together. I've used a sheet of thin 0.3mm resin impreginated 100% carbon fibre cut into strips to make the rib. The strips were then glued togeter in a laminated fashon with gaps in between.
[Edited on 21-8-2004 by iswinkels]
2443TT 路
Next i reinforced the rib with fiberglass, and created a wide base to allow it to be glued into the CF decklid. After a little glassing and shaping, the end result is a rib that is very rigid , yet has a low profile and will not foul on the engine.
After lining up the rib I glued one side, then the other using reinforced fiberglass body filler as the glue. in both cases I used a clamp to hold the rib in place.
2443TT 路
One side glued...
2443TT 路
And then the other....
2443TT 路
Next is the hard part... hinges....
I cut a pair of good hinges out of a steel engine lid and went about making up mounts for them out of carbon fiber sheet. With the basic shape correct, I drilled holes and mounted the hinges.
I then back filled the entire mount with reinforced filler. Yes its a little on the overkill side, but I need the surface to have it glue properly to the CF lid. 0.3mm carbon fiber glued at a 90 degree angle to the lid would otherwise not hold.
I didn't take pictures of this stage... as I wasn't sure it was actually going to work out. Fortunently it did.... and here's the pics...
2443TT 路
After some careful measurements and a trial fitment usng thin double sided tape to hold it all in place I then glued the hinges to the decklid.
With both hinges glued on, i then trial fitted the lid and it is dam near perfect. Here's a pic of the hinge gluing...
2443TT 路
Next and again after measuring everthing 5 times I carefully drilled the hole for the engine lid T handle. I drilled the hole smaller than it needed to be, and then used a fine grinding bit to machine out the oval hole.
This was done because anyone that has ever tried to drill carbon fiber will know that the drill bit has a tendancy to want to follow the grain of the CF. This results in the hole moving from where you want it to be, and if your realy un-lucky you can tear the carbon and rip a massive hole in it.
After making an oval hole for the T handle sleve I then wrapped the sleve (chrome bit that goes aroung the T handle) in thin tape and pushed it into the hole. Fiberglass resin does not stick to this plastic tape.
To support the t handle it is necessary to re-inforce that section to be about 5-6mm thick. To do this is built the area up with fiberglass. When it sets I can then remove the chrome bit, remove the tape and then have a perfect fit. I've also re-inforced around the rib a little, just to be in the safe side.
And here's a picture...
Cam 路
dude that engine lid looks mad! Are you going to keep it bare or paint it?
Dave_Bugz 路
how much have you spent dare I ask?
2443TT 路
And here's the finished result! Sweeeet I'm pretty happy with how the car's looking now. Just need to put on the passenger side mirror and the bonnet VW badge and the exterior trim will be nearly finished.
Filled up at a servo last week and after paying came out and there was a group of 6 people around the car. It is certinly getting some attention.
Still got tons to do with the interior. Soundproofing, headliner and tidying up the wiring.
[Edited on 22-8-2004 by iswinkels]
2443TT 路
And here's another...
Oh, and about what the car has cost... I prefer to say that real VW enthuesiests don't keep recepts. If I had to guess I'd say around 30-35K. Something around that....
[Edited on 22-8-2004 by iswinkels]
AdrianH 路
Ian,
Have you got the new engine in there ? - I cant belive how quickly you got it all together, awesome job !!
Adrian
Gibbo 路
That is a seriously smooth ride my man, a huge pat on the back for you.
Its a credit to all your hard work.
reub 路
Looks great mate.....good idea getting the lid and how you ended up mounting it hey.....馃榾
GL1972 路
Very slick job! Does that cost put a value on your labor? How much of it did you farm out?
I counted labor on mine to date and it came to 1100 hours so far. I am also amazed on how you did it so quickly.
This is a time consuming expensive hobby but would you do anything else?
We should start another thread "What does it take to create a sweet ride"
Brendan
2443TT 路
Well it appears to have come together fairly fast, but truthfully i'd been collecting parts for the past two years. Then all the running gear came from my red '66 in the form of a rolling chassis. The dashboard was a direct transplant from the old car too.
Hours.... dam I couldn't even begin to guess.... most definatly the most time consuming hobby i've ever had. 馃檪
And AdrianH, na it's not powered by the 2380 turbo yet. Still some major work to to there too. New oil system based on a 3 stage honda dry sump pump, shorter rods (5.394" instead of the 5.6" rods), and i've still got to order the cylinder heads yet too. Its probably another 6 months off, as i've still got to finish the interior of my car, and I haven't collected all the gear to do that yet.
Power window conversion inside the next 3-4 weeks is the next project, along with a LOT of sound proofing.
Cheers all, and thanks for the feedback!
Craig Paton 路
Hey Ian
If ever I am unfortunate enough to have my my car in a show where your car is in attendance, could you make sure that your car is nowhere in the vacinity of mine!!!!!!
That would be greatly appreciated!!
Cheers Craig 馃槈
2443TT 路
No problems, but I will be at the next Vala event! I can't miss that one.
Cheers,
silver 路
iswinkels wrote:Oh, and about what the car has cost... I prefer to say that real VW enthuesiests don't keep recepts. If I had to guess I'd say around 30-35K. Something around that....
[
You do, if you can tax deduct the "Repairs". My Kombi and Beetle are company car's and buisiness registered Ha Ha!
I look forward to seeing your car as well Ian.
S