nils Fahrvergnugen
971 posts · joined Jan 2008 ·
You're a man of many talents smiley
Quit calling rust patina
Alyce the Baja
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Thanks mate. That means a lot coming from you. I've seen the work that has gone into your car.nils wrote:You're a man of many talents smiley
I have a quick question for you. When you put the hanging pedal in you car for the accelerator, do you need to get that approved and blue plated?
I'm considering the possibility of underslung pedals for mine.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Well seeing as none of you gave me any ideas I opted to chop the whole bottom off the airbox and rotate by 180° and plastic weld it all back together.
I did it with the element in and top clipped in place to try and keep it all square and stop it pulling itself out of shape from the heat.
All welded in place 😘
I also picked up some new rubber mounts for the box on Friday. Plan is to throw the engine back into the car tomorrow and fab up a frame to support the box in place where I want it.
More soon.
Smiley 🙂
I did it with the element in and top clipped in place to try and keep it all square and stop it pulling itself out of shape from the heat.
All welded in place 😘
I also picked up some new rubber mounts for the box on Friday. Plan is to throw the engine back into the car tomorrow and fab up a frame to support the box in place where I want it.
More soon.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Well I've made some good progress since the last post.
Have changed the way to box is being mounted. When I sat it in place with the 3 rubber mounts bolted to the bottom None of them lined up nicely with anything to mount to.
So I'm now running two mounts on the fanhousing and one off the top of the throttle linkage pivot.
I borrowed a nutsert gun and put some threads in the shroud for the mounts. These are a nifty little tool, they are basically a pop rivet with a thread down the middle of them. I might even look into buying myself a kit.
Then I had somewhere to mount two of the mounts for the box.
Smiley 🙂
Have changed the way to box is being mounted. When I sat it in place with the 3 rubber mounts bolted to the bottom None of them lined up nicely with anything to mount to.
So I'm now running two mounts on the fanhousing and one off the top of the throttle linkage pivot.
I borrowed a nutsert gun and put some threads in the shroud for the mounts. These are a nifty little tool, they are basically a pop rivet with a thread down the middle of them. I might even look into buying myself a kit.
Then I had somewhere to mount two of the mounts for the box.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
The third central mount is bolted onto the frame for my carby linkage pivot.
And with the airbox base in place. You can see everything has plenty of clearance 👍
Smiley 🙂
And with the airbox base in place. You can see everything has plenty of clearance 👍
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
I had some super duper spacers rings made up to adapt the Commodore inlet flanges onto the Kadrons. You can also see the cross bar that has been welded into the tube.
Spacer goes here.
And then this fits over the top. And bolts down using the factory Kadron aircleaner mount threads.
Smiley 🙂
Spacer goes here.
And then this fits over the top. And bolts down using the factory Kadron aircleaner mount threads.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Look what showed up in the mail today.
At least 5hp per silicon bend I think!
They go here like this.
And the alloy tube will be trimmed to length and fit in the gap like so.
Smiley 🙂
At least 5hp per silicon bend I think!
They go here like this.
And the alloy tube will be trimmed to length and fit in the gap like so.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
I'm going to have to pull the engine and cut off the stock decklid hinge mounts.
They are in the way.
And worse on this side. Nothing the grinder can't fix.
Aside from that the clearance is very good. Doesn't rub on hit on anything. I've always wondered what the hump in the engine scoop of the Baja kit is for, it's so you can fit an airbox!!
Thanks for reading, more very soon.
Smiley 🙂
They are in the way.
And worse on this side. Nothing the grinder can't fix.
Aside from that the clearance is very good. Doesn't rub on hit on anything. I've always wondered what the hump in the engine scoop of the Baja kit is for, it's so you can fit an airbox!!
Thanks for reading, more very soon.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
BlueV2 Seriously Crusin Dubber
193 posts · joined Apr 2008 ·
Smiley, why do you have a spark plug in your exhaust system ?
Nice airbox by the way ❗
Nice airbox by the way ❗
Sharpbuilt V2, EJ25, Subaru 5 Speed, Falcon rear discs, Heater & A/C, Rack Steering
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
That's where my O2 sensor goes. I had it out when I took the engine down to the Gold Coast and we rebuilt it. And I knew that we were going to run it up, so I plugged the hole. The large spark plug is the same thread size as an O2 sensor.BlueV2 wrote:Smiley, why do you have a spark plug in your exhaust system ?
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
BlueV2 Seriously Crusin Dubber
193 posts · joined Apr 2008 ·
Huh, I thought you were using it to light the afterburner !! lol
Sharpbuilt V2, EJ25, Subaru 5 Speed, Falcon rear discs, Heater & A/C, Rack Steering
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Hahahaha Yeah! Shoot a nice plume of flame out onto the ground.BlueV2 wrote:Huh, I thought you were using it to light the afterburner !! lol
She's not running that rich!!
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
So I got stuck in last night and finished off my airbox setup.
I needed to make room on the firewall area where the hoses looped around.
So I got stuck in and trimmed 90% of the drip rail off. As well as the decklid hinge mounts and prop srping mouhttp://forums.aussieveedubbers.com/post.php?action=reply&fid=25&tid=80275nt.
Smiley 🙂
I needed to make room on the firewall area where the hoses looped around.
So I got stuck in and trimmed 90% of the drip rail off. As well as the decklid hinge mounts and prop srping mouhttp://forums.aussieveedubbers.com/post.php?action=reply&fid=25&tid=80275nt.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
They I trimmed the alloy tubes down to length.
A very easy way to mark tubes evenly and straight it to put a hose clamp on and tighten it up. Then use this as a guide to make your cut. This is a very good method of getting straight cut when you are cutting a front beam to fit adjusters.
It wasn't long before I had this 🤘
Looking ready to ruin some 4WDs day now 😀
Smiley 🙂
A very easy way to mark tubes evenly and straight it to put a hose clamp on and tighten it up. Then use this as a guide to make your cut. This is a very good method of getting straight cut when you are cutting a front beam to fit adjusters.
It wasn't long before I had this 🤘
Looking ready to ruin some 4WDs day now 😀
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
SebastienPeek Custom Title Time!
1,657 posts · joined May 2011 ·
Looks the goods Smiley!
Can't wait to see it back in Alyce.
Are you expecting to notice any difference whatsoever?
Can't wait to see it back in Alyce.
Are you expecting to notice any difference whatsoever?
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
It wasn't long before I had it fitted up to see if everything cleared. I'm happy to report that to clears the firewall completely!! Only thing I had to do was slide the coil an inch or two lower in it's clamp to clear the LHS pipe.
And it all clears the engine scoop with plenty of room to spare.
As far as servicing goes, all I have to do is loosen the two hose clamps onto the carbies, undo the clips on the airbox and it wiggles out easily!
I have fitted a K&N oilable filter element to the airbox, and am looking to run a prefilter or two on the inlet to the airbox before I take it offroad.
I'm sure that this setup should work a great number of times better than the old setup, and prevent me prematurely wearing out the rings and the bores again. All I have to do now is finish connecting the engine up and refit the rear barwork. Then I can start running her in.
I'm interested to see if the induction noise will be different, hopefully it's a little quieter.
Smiley 🙂
And it all clears the engine scoop with plenty of room to spare.
As far as servicing goes, all I have to do is loosen the two hose clamps onto the carbies, undo the clips on the airbox and it wiggles out easily!
I have fitted a K&N oilable filter element to the airbox, and am looking to run a prefilter or two on the inlet to the airbox before I take it offroad.
I'm sure that this setup should work a great number of times better than the old setup, and prevent me prematurely wearing out the rings and the bores again. All I have to do now is finish connecting the engine up and refit the rear barwork. Then I can start running her in.
I'm interested to see if the induction noise will be different, hopefully it's a little quieter.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
I expecting to notice a lot less oil consumption, and an engine life of more than 6 months/25000km.SebastienPeek wrote:Looks the goods Smiley!
Can't wait to see it back in Alyce.
Are you expecting to notice any difference whatsoever?
Hoping the induction noise might be a little less and the filter is a lot more easy to service now too. And it's easier to fit a prefilter.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Just a quick update.
I've been driving the car to work and around, basically as much as possible to run the new engine bits in.
I've done over 1000kms in the last week since I started driving her again.
Fuel economy is a little worst than it was, I've averaged between 13.2 and 13.5L per 100km. But all the tanks have been very close together in this range which I think is a good thing.
The A/F ratio gauge indicates that she's running rich throughout the rev range. So I'm sure with a few adjustments I can get a little more economy out of her. Getting down into the 11s would be great, we'll see how things go.
I'm currently working on fitting a digital speedo (with a twist) to the car so I'll put some posts up of that when I get it all sorted and ready to go in.
Smiley 🙂
I've been driving the car to work and around, basically as much as possible to run the new engine bits in.
I've done over 1000kms in the last week since I started driving her again.
Fuel economy is a little worst than it was, I've averaged between 13.2 and 13.5L per 100km. But all the tanks have been very close together in this range which I think is a good thing.
The A/F ratio gauge indicates that she's running rich throughout the rev range. So I'm sure with a few adjustments I can get a little more economy out of her. Getting down into the 11s would be great, we'll see how things go.
I'm currently working on fitting a digital speedo (with a twist) to the car so I'll put some posts up of that when I get it all sorted and ready to go in.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
big_ash Commited Dubber
54 posts · joined Dec 2010 ·
Looks the goods! 🙂
Vw crazy 🤓
kaiisons Seriously Crusin Dubber
119 posts · joined Mar 2009 ·
hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
Joel Now containing 100\% E-Wang
9,368 posts · joined Feb 2006 ·
Ready to start on mine?
it's still in the "I haven't worked out how the hell I'm gonna do this" stage at the moment.
You make plastic welding look so easy.
it's still in the "I haven't worked out how the hell I'm gonna do this" stage at the moment.
You make plastic welding look so easy.
ian.mezz I never said, I could write or spell
3,913 posts · joined Sep 2004 ·
looks like there is a hole in the side of the lower half.???kaiisons wrote:hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
😂🤪😂🤪😂
car forums. where a lot of peoples good intentions end up taking a good old car off the road forever never ever to see the road again. 🥲
car forums. where a lot of peoples good intentions end up taking a good old car off the road forever never ever to see the road again. 🥲
1303Steve Scirocco Rare
8,650 posts · joined Aug 2002 ·
[/quote] I'm considering the possibility of underslung pedals for mine.[/quote]
Hi
Love your work.
Do you know why Dr. Porsche designed the pedals that way as in bottom hinged?
Have look at how your ankle joint works when pushing on the brake or clutch pedal then imagine how it would work with underslung pedal, you will see that underslung pedals cause the ankle to try to bend the wrong way.
Larry Perkins amongst other V8 racers set up bottom hinged pedals to reduce fatigue on the ankle joint, we will probably never have this problem but I thought I would point it out.
Steve
Hi
Love your work.
Do you know why Dr. Porsche designed the pedals that way as in bottom hinged?
Have look at how your ankle joint works when pushing on the brake or clutch pedal then imagine how it would work with underslung pedal, you will see that underslung pedals cause the ankle to try to bend the wrong way.
Larry Perkins amongst other V8 racers set up bottom hinged pedals to reduce fatigue on the ankle joint, we will probably never have this problem but I thought I would point it out.
Steve
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
As Ian has suggested there is a hole in the forward facing edge of the bottom half of the airbox. I faces towards the fanhousing. There is plenty enough gap there to allow enough airflow. The hole is the front of the box is 55x105mm which works out to 5775 square mm.kaiisons wrote:hey i was wondering if you could explain how the air actually gets into the air box. you might be running more rich because of a lack of air flow.
I filled the car up again this morning and am happy to report that the last tank I got 12.4L per 100km. Which is a great improvement, I guess everything is starting to bed in properly. I wouldn't say that it's running rich due to lack of airflow, just that the mixture screws need adjusting slightly.
Plastic welding is easy!!! Send it up my way and I'll be happy to glue the stuff together for you 🤓Joel wrote:Ready to start on mine?
it's still in the "I haven't worked out how the hell I'm gonna do this" stage at the moment.
You make plastic welding look so easy.
I've been using my gas soldering iron, the flame is adjustable which helps regulate the tip heat. When plastic welding sometimes you want to throw a fair bit of heat in to get the puddle flowing and other times you want low heat to prevent you from blowing holes in it.
This is my one that I've been using. It comes with a variety of tips so I've picked the one that suits plastic welding the best.
The tip I'm using has a 'pie slice' cross section. I've found it the best one in the set for welding. You can use the sharp edge to cut through the plastic, the large flat sides are good for smoothing and the rounded back is great for getting into concave hollows and tight corners.
I hope this info helps you out.
1303Steve wrote:HiI'm considering the possibility of underslung pedals for mine.
Love your work.
Do you know why Dr. Porsche designed the pedals that way as in bottom hinged?
Have look at how your ankle joint works when pushing on the brake or clutch pedal then imagine how it would work with underslung pedal, you will see that underslung pedals cause the ankle to try to bend the wrong way.
Larry Perkins amongst other V8 racers set up bottom hinged pedals to reduce fatigue on the ankle joint, we will probably never have this problem but I thought I would point it out.
Steve
You make an interesting point Steve. Something that I would not have thought about. I figured that because most newer vehicles have underslung pedals that is would be the superior option. I was more wanting to get the pivots etc up out of the crap as my footwell often gets full of sand and mud etc, despite how often I clean it all the moving parts cop a lot of contamination. I figured that moving the mounts up onto the firewall would reduce the crap getting into the moving parts and stop them wearing out as quickly. I also planned to upgrade to a hydraulic clutch at the same time.
Thank you for you input, I guess it's more info to process before I decide to make the swap or not 😵💫
Thanks to everyone else for their comments. There's no point updating a build diary unless people are going to read it and leave some feedback 😀
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Have got her down to a best of 12.32L/100km when I filled her up last night.
Due for a valve set when she's cold early in the morning before I go to work, and a service tomorrow after work when she's hot 😀
Smiley 🙂
Due for a valve set when she's cold early in the morning before I go to work, and a service tomorrow after work when she's hot 😀
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
1303Steve Scirocco Rare
8,650 posts · joined Aug 2002 ·
Hi Smiley
I have regularly clean my pedal area as well, I can see your reasoning to go underslung
I'm not sure if you already commented or not, does the filter make any difference to induction noise?
Steve
I have regularly clean my pedal area as well, I can see your reasoning to go underslung
I'm not sure if you already commented or not, does the filter make any difference to induction noise?
Steve
matberry Moderator Go hard or go home
8,114 posts · joined Mar 2006 ·
Good one Smiley.
I'm with Steve on the pedals, pet hate converting beetles to hung pedals👎👎👎
I'm with Steve on the pedals, pet hate converting beetles to hung pedals👎👎👎
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
It's not of any noticeable difference.1303Steve wrote:I'm not sure if you already commented or not, does the filter make any difference to induction noise?
Steve
Maybe a tiny bit quieter. I can't really tell over the exhaust.
I really need to get some more sound proofing into this car, it's very loud for a daily driver. I'll probably be deaf soon. Worth it though, getting to drive my aircooled Volksie and watch all the fools with their 'new' cars.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Is it for the above mentioned reason?matberry wrote:Good one Smiley.
I'm with Steve on the pedals, pet hate converting beetles to hung pedals👎👎👎
Or something else you don't like about the conversion?
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
matberry Moderator Go hard or go home
8,114 posts · joined Mar 2006 ·
I've always been most comfortable with floor pivot, I also always considered it to be more 'correct' for our ankle movement and felt under hung are purely a function of front engine engineering. Never realised Dr Porsche considered it a must for the same reason..... 🙂
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE