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 1303Steve
A.k.a.: Steve Carter
Scirocco Rare
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| posted on March 10th, 2013 at 08:13 PM |
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Hi Rich
I saw on another forum (I'm not a stalker) that you found it much heavier to operate than the old clutch, mine took a bit of getting used to but I
thought it was maybe my set up causing the heaviness.
Steve
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ricola
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| posted on March 10th, 2013 at 09:13 PM |
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lol, yes it's much heaver and shorter. I'm starting to think that the old one was way past its best as I don't think there should be this much
difference. I may well investigate a different size master cylinder to make it lighter and longer, seems to be quite a common thing to do on Ultimas
which also use the G50..
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reub
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| posted on March 10th, 2013 at 11:24 PM |
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I should weigh my pressure plate while it is all apart... I picked up a brand new 964 pressure plate by chance too which is lighter than the one I've
been using. Need to measure it all up and see if it is usable...
Reub
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ricola
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| posted on March 10th, 2013 at 11:33 PM |
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I'd be interested to hear if it works, all listings I've seen have different clutches for short & long G50s but I don't know what the
differences are..
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ricola
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| posted on April 25th, 2013 at 06:29 AM |
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The mapper was booked up solid for a while but I'm booked in for May 14th, I've done about 1200 miles now and given it an oil change and it's all
going very well. As I do I got bored with nothing to do so thought I'd work on the heating system.
A problem I had on a previous kit car was that the heating system was ducted so efficiently with the intake in a high pressure zone that I would
always get warm air coming through the system into the car. I couldn't have the fans on with ambiant temperature air as the heater matrix was part of
the thermostat bypass flow. This was a particular problem during some heavy summer rain where I needed a good amount of air flow to keep the screens
de-misted and my only option was hot heated air which turned the interior into a steam room! The solution is to fit a valve which can bypass the
matrix but still enable constant flow, handily Ford fit one to many of their small cars so I bought one.
The valve could be connected up to an on/off switch but a better solution (as well as how it is used in Fords) is to use a low frequency PWM
controller, this gives proper temperature control by cycling the valve on and off depending on demand of a rotary switch which I have fitted in the
glovebox. Mine came from ebay as a generic part but was modified by the seller to reduce the frequency to something more suitable. The valve connector
was a generic mini timer type that was also from ebay.
Finally getting around to fitting the valve in the car after cutting off superfluous brackets, a quick test of the electrics to make sure it was
fitted the correct way around and it's in!
A test in the car and I'm extremely happy with how it works, the temperature is easily adjusted and changes surprisingly quickly.
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ricola
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| posted on July 28th, 2013 at 05:17 AM |
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As the car is more or less done now I thought I'd post a bit of a summary of the final spec and some finished pictures (still waiting to get a proper
photoshoot sorted!). In the mean time I've had it on the test track at work and got it up to an easy 150mph (GPS not speedo) and there was plenty
more in it. Just need to give it a clean ready for a trip over to Spa next weekend..
[B]Body[/B]
oMain body restored with new heater channels, strengtheners, bulkhead, etc etc
oSpare wheel well modified to take main radiator and charge-cooler radiator
oFuel tank extended, baffled and fitted with internal up-rated fuel pump (HRC 310lpm)
oRear end removable on frame, VW bus inspection hatch above engine
oFront wings: 2” wider in fibreglass
oRear wings: 40mm wider in steel with forced cold air intake incorporated into left hand wing
oK&N panel air filter built in to inner wing, with water drain
oLengthened bumper irons with stock bumpers
oRepaint in original colour (Schwartz Metallic)
oGerman Sonnenland roof
[B]•Chassis[/B]
oCustom framehorns, torsion housing central section removed
oCustom perimeter frame rails with one-off bead-rolled floors, finished in epoxy mastic 121.
oOBP reverse mounted pedal box with twin brake master cylinders for adjustable bias and hydraulic clutch under false floor
oFront: Kerscher coil-over struts, heavy duty anti-roll bar
oRear: IRS with Protech coil-over dampers and swing axle length torsion bars, 944 anti-roll bar
o19” Porsche Carrera Sport wheels, 10j rear, 8,5j front
oVredestein Ultrac Sessenta tyres, 265/30R19 & 235/35R19
oPorsche 911 (996) brembo brakes front & rear
oBraided hoses, 911 fluid reservoir.
oSpacesaver 996 spare wheel
[B]•Powertrain[/B]
oRebuilt subaru EJ257 shortblock (2.5l STI), forged supertech pistons, rebuilt V4 sti heads, ARP 11mm head studs, external oil breather catch tank,
shortened/extended sump with RCM baffle plate, Garrett SC46 turbo, ported headers with custom 2” crosspipe, 3” bellmouth from turbo back,
magnaflow 3" muffler, Nismo 740cc injectors, ESL daughterboard mapped by Bob Rawle, Aeromotive FPR on reversed parallel fuel rails, new-age subaru
coilpack conversion. Estimated 400-450bhp, 450ftlbs.
oCustom charge-cooler system with bosch water pump and Pace pre-rad, inlet manifold spacers/insulaters
oCooling system modified to external thermostat with Pace sierra cosworth radiator, fans controlled by ECU
o1989 Porsche 911 ‘G50 shortnose’ transaxle fitted with rebuilt 964 RS LSD (80/20). 930 CVs, aftermarket axles and drive flanges, KEP uprated
Porsche stage 1 clutch (550ftlbs)
[B]•Interior[/B]
•Square weave carpets
•Heated Porsche 996 sports seats and seatbelts
•Rear seat modified to clear transmission tunnel
•Dashboard widened to fit early Porsche 924 gauges with additional Stack Oil pressure and turbo pressure gauges. Mini switches.
•Seats and dash re-trimmed in saddle tan leather by Auto-trim, Leicester
•Alpine CDA-X001 head unit, Rainbow component speakers up front in one-off fibreglass foot well enclosures, pioneer rear speakers in kick panels
•One-off heater system built into stock duct system, stock dash controls with t25 fan switch & electronic Ford heater valve
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 Bizarre
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The artist formerly known as blue74l
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| posted on July 28th, 2013 at 08:03 AM |
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W........O........W
Unbelievable.
I know the motor is brilliant, but it is the art direction - the visual package that just blows me away.
The interior of this just beautiful.
Futue te ipsum!!!
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1303Steve
A.k.a.: Steve Carter
Scirocco Rare
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| posted on July 28th, 2013 at 09:10 AM |
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Beautiful Rich, any idea on horsepower/kilowatts? Have you weighed the car yet?
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Camo
A.k.a.: Kev
Custom Title Time!
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| posted on July 28th, 2013 at 09:59 AM |
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That is exactly what the modern day Beetle should look like and fitted with those appointments 
Kev
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Flintstones
Custom Title Time!
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| posted on July 28th, 2013 at 12:04 PM |
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All class mate
Congrats on building such an incredible car Rich
Cheers
D
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ricola
Wolfsburg Wizard
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| posted on July 28th, 2013 at 07:32 PM |
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Cheers guys, it was important for me to not build it too much to any particular style to keep it timeless and subtle.
| Quote: | Originally
posted by 1303Steve
Beautiful Rich, any idea on horsepower/kilowatts? Have you weighed the car yet?
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It hasn't been on a dyno but the mapper reckoned comfortably over 400bhp and I didn't want over 450bhp/ftlbs to save my rods. The light billet
compressor wheel really helps with early spool, 1 Bar by 3000rpm easily.
When I had it on the brake tester for its MOT (annual UK road worthiness check) it weighed 1200kg full of fuel/fluids (no driver) with a 60/40 axle
split which is pretty much what a 911 is so I'm happy with the distribution, I guess I could move the battery up front and I might fit a dual circuit
brake booster as they are a bit heavy. Not a light car but I've built it with all the toys and it has PLENTY of traction in the dry..
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vlad01
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| posted on July 29th, 2013 at 01:26 PM |
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very nice! one of the best for sure.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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lou0060
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| posted on July 29th, 2013 at 09:42 PM |
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if only the designers at VW were watching.......
certainly the pick out of the current 4 seater cabrios on the market today....
well done Rich!
1971 karmann ghia Cabrio - Cruising 
1963 beetle Sunroof - gathering dust 
1968 race beetle - twin turbo Subaru - stress relief 
1960 beetle - old school low & slow  |
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ricola
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| posted on September 6th, 2013 at 07:13 AM |
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Road trip to Spa was awesome, loads of cars I've never seen before and after seeing other pictures plenty I missed so I'll definitely be back! Was
great to get a chance to drive around the track and got a top 20 award which finished off a top weekend  Good to meet birdman/Ron after making the big trip over too!
I also finally got the photoshoot for Volksworld done with some strange attachments, should be some good action shots and I can't wait to see them
(http://www.stevehallphotography.net).
After the trip to Spa, the race style compact boots finally gave up with dealing with the CV angle. They are mainly designed for race cars and are
basically an inverted cone with little give so not surprising really. They were necessary to clear the coil-over springs. This picture is from
underneath with the car on a 2 post lift and the suspension at full rebound so definitely not the worst position, the damper swings closer to the axle
at ride height.
The long term fix was always to relocate the coil-over. I had a spare pair of trailing arms from a 944, these are identical to the beetle ones with
the exception of some internal strengthening.
I made up new curved section to take a scallop out of the arm and also reweld the lower damper mount about 15mm further forwards.
All back together ready for clean up and paint.
Better view showing the additional clearance made.
As before this is with the suspension in full droop but now with a nice big silicone off road style CV boot that is designed for much more angularity
than I will subject it to. At ride height I can get a finger between the spring and boot so clearance is no longer an issue. While I was at it I also
fitted the 944 spring plates with the built in capability of a camber bolt anti-roll bar fitting to set the camber, it is also designed to take a toe
adjustment tool. I had to lose the ride height adjustment due to clearance problems with the wheel but with the adjustable coil-overs this really
isn't an issue for me...
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1303Steve
A.k.a.: Steve Carter
Scirocco Rare
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| posted on September 6th, 2013 at 10:02 AM |
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Hi Rich
Great thinking as usual, well done on the award, I'm taking Birdman for a spin tonight in my bug.
Steve
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madness726
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| posted on September 18th, 2015 at 06:15 AM |
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Nice build. I went thru your build, But never saw if you made a master mold for the front spoiler? and if you make some to sell or if it was just a
one off.. I want one like that for my super since I dont run bumpers..
Gotta work on the Nut behind the wheel before you start fixing bolts on the Car.
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ricola
Wolfsburg Wizard
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| posted on September 18th, 2015 at 06:34 AM |
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Sorry, the spoiler mock-up ended up being so strong I just tidied it up and used it as was! The car is still going great, even used it as my daily
through last winter (in the snow!) with no issues. Just bought a Tesla Model S as my daily and a massive contrast to the weekend toy!
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madness726
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| posted on September 18th, 2015 at 06:46 AM |
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I will just copy what you did and make one myself as well..
Gotta work on the Nut behind the wheel before you start fixing bolts on the Car.
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