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 matberry
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| posted on September 19th, 2011 at 10:57 PM |
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Crikey mate, you didn't like the slip joints did ya. Yeah.....yeah.....too high. Might be awkward fitting once all welded together, hopefully it will
flex enough.
Good work, make it how you want it 
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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 Smiley
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| posted on September 20th, 2011 at 07:19 AM |
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| Quote: | Originally
posted by matberry
Yeah.....yeah.....too high. Might be awkward fitting once all welded together, hopefully it will flex enough.
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Yeah, too high. And it'll fit, I'll make it fit 
Smiley 
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Smiley
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| posted on September 20th, 2011 at 07:22 AM |
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Also, I'm fitting flanges to the J-pipes so it's easier to fit number 1 and 3 exhaust tubes. If that's what you meant. I'll be able to put the
rear half on the bolt the tubes onto the front.
Then I just need to work out how and where my muffler is going 
Smiley
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Smiley
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| posted on September 20th, 2011 at 10:46 PM |
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Now where were we? Exhaust!
Here is the collector sitting in place ready to be welded.
After three of the pipes were tacked into place I removed one of the tubes so I could weld out the others more easily. It was just more of a pain in
the ass to weld the last one, but got there in the end.
Then I cut the J-tubes off and added in the flanges a wanted (can you tell I don't like slip joints yet?)
Now I just need to sort out the muffler orientation once the engine and cage are fitted
Smiley
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Smiley
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| posted on September 20th, 2011 at 10:52 PM |
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And I couldn't resist throwing the engine into the car, even if it's only temporary. I wanted to make sure the carbies and aircleaners were going to
clear the body.
I had to removed the top plate and element of the filters, but beside from that the whole engine just slots neatly into place. Got to love a Baja for
ease of access 
I'm not sure if the tops of the aircleaners are going to clear my engine scoop, but that's a hurdle we'll overcome if the issue arises.
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:10 PM |
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Engine back out!
Got the vents on the back fitted up nicely. Had to get a little foam to seal some of the gaps.
While the donk was out these came out of the little baggies
Axles in!
Smiley
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SebastienPeek
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| posted on September 21st, 2011 at 11:17 PM |
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Nice work Smiley!
Looking great, when you reckon it'll be back on the road?
I have to admit, I love that colour on the engine. It is awesome!
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Smiley
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| posted on September 21st, 2011 at 11:19 PM |
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Engine bolted back in with exhaust.
Cage added.
This is the room I have to fit a muffler in.
I'm sure I can make is fit. More pictures on that in a minute.
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:24 PM |
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| Quote: | Originally
posted by SebastienPeek
Nice work Smiley!
Looking great, when you reckon it'll be back on the road?
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Thanks man. I'm hoping to start the new engine for the first time tomorrow and run the cam in. Then I'll be driving as much as I can from there.
Still lots of work to be done first. Might have to bleed those brakes too...
| Quote: | Originally
posted by SebastienPeek
I have to admit, I love that colour on the engine. It is awesome!
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Thanks. To be honest it's just primer grey. Which matches the colour I've had other parts on the car powdercoated. I'm going to get the engine tins
and barwork powdercoated in the same grey down the track too.
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:30 PM |
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With the rear cage fitted I ran into this awkward situation.
The external oil filter doesn't clear the barwork 
The supplied bracket hangs too low.
So I'm going to make a new one tomorrow that'll lift the filter up a little and tilt it clockwise slightly to keep the hoses aimed under the exhaust
and at the pump.
Plan is for it to sit around about here.
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:33 PM |
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Another clearance concern of mine was the top of the new aircleaners to the baja engine scoop.
As you can see in the pictures there's plenty of room.
The same can't be said for my old engine cage and the new exhaust though. And this is without the muffler bend on the top. Mattberry would be proud
of the height
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:36 PM |
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A few more little jobs ticked off the list.
New rear shocks fitted.
Oil pressure switch and pressure sender fitted.
Oil temp sender fitted, had to drill and tap the Type 3 dipstick plate.
Dizzy fitted.
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:39 PM |
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I said I'd get back to the muffler right?
Plan is for it to hang here like this. All I need to do is can the tube off the top and basically weld it on 180° from where is is now. And make a
new support for down the bottom somewhere. And make cut the tip off to stop morons melting their knees on it, namely me!
Smiley
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Smiley
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| posted on September 21st, 2011 at 11:54 PM |
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Things still left to be done.
Make new filter mount.
Put oil in transaxle and engine.
Connect shifter coupler to gearbox.
Bleed brakes.
Install and adjust handbrake.
Plug holes in manifolds.
Add proper spacers under axle nuts.
Modify muffler to fit.
Mount coil to firewall.
Fit leads and engine wiring.
etc etc etc etc.
What have I missed? Any more ideas?
Smiley
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BlueV2
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| posted on September 22nd, 2011 at 10:47 AM |
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Not sure if it matters that the external oil filter is on an angle, but I would want good clearance between the hoses and the exhaust. That is the
hotest part of the exhaust, and you wont find out about the leak until you have been running hard down the freeway for a while. I am sure you have all
that covered though :-). Its all looking really good.....well done.
Sharpbuilt V2, EJ25, Subaru 5 Speed, Falcon rear discs, Heater & A/C, Rack Steering
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Smiley
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| posted on September 24th, 2011 at 12:12 PM |
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Ok. Here's what I did Thursday night.
New bracket for the oil filter was made.
I cut down a stubby cooler and made a NASA spec rock deflection apparatus
Made up the oil hoses and fitted them. I discovered yesterday that I put them on around the wrong way, and have since swapped them correctly.
There is quite a bit of clearance to the exhaust, but I'm also going to put some exhaust wrap on the section near the hoses. I will try to get some
heat sheathing for the hoses at work too.
Smiley
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Smiley
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| posted on September 24th, 2011 at 12:21 PM |
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Coil has been mounted to the firewall. A few reasons for this. It's not going to vibrate loose, it's mounted in out of the weather, plus I didn't
want to mount anything on my pretty fanhousing
Fuel lines and wiring was completed. Still needs a massive tidy up and waterproofing.
I got a heap of some P-clamps from work in order to tidy up the fuel lines and wiring. Here is one I put in place to hold the #3 and 4 leads up off
the exhaust. It looks very neat.
Smiley
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Smiley
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| posted on September 24th, 2011 at 12:26 PM |
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Still on Thursday night. I got in and got the exhaust finished off.
As luck would have it I had an exhaust bend lying around that was perfect for my needs. I was going to mound the muffler like this.
This orientation had the tip poking out nicely from under the back of my cage. But I was unhappy with the way the muffler and top bend were sitting.
And I discovered if I spun the muffler 180° and faced the tip towards to front of the car the fit was much better.
The bend was trimmed to length and tacked in place. Then tried on the car.
Smiley
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Smiley
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| posted on September 24th, 2011 at 12:36 PM |
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Welded out
I had to spin the tip 180° and weld it back on. I also trimmed in right back too. Still hangs a little low for my liking. Time will tell to see if it
catches on anything.
You can also see in the picture that the exhaust is higher than the fanhousing  Mattberry eat your heart out
I even managed to use the factory style clampy mount to support the bottom of the muffler from vibrating. Please excuse the dodgy weld. I did this one
just after I ran out of gas on the MIG. Luckily enough I got everything else welded before I run out.
Smiley
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Smiley
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| posted on September 24th, 2011 at 12:45 PM |
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Yesterday afternoo I had a couple of little wiring issues to finish. New oil pressure sender. Then I added oil. Roughly set the timing. Cranked her
over till I got oil pressure. Then started her and run the cam in!!!
Here's a few pictures of me running the cam in. I've bought a tacho for the car and I wired it up to the coil, so that's what I'm watching.
And here's a couple of quick movies my dad took. Engine sounds tough. between 2500-300RPM it's not super loud, which I'm stoked with because
that's where it'll be sitting when driving to work on the highway. She ran quite well given I haven't touched the carbies.
http://s933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/?ac...
http://s933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/?ac...
Enjoy! I'm off to tune the carbies and set the timing
Smiley
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SebastienPeek
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| posted on September 24th, 2011 at 12:59 PM |
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Smiley!
Seems someone has definitely been busy!
That oil filter is great, that mount is even better!
That exhaust mounting is looking tough, and sounds even tougher.
Glad you're getting there, can't wait to see a video of it in action roaming around a forest somewhere!
Oh, and your wiring job, excellent in keeping in bloody tidy!
Looks awesome.
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11CAB
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| posted on September 24th, 2011 at 01:14 PM |
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Good to see its getting close Fraser isnt far away
Josh turned 16 today and got to add this to his Baja......
65 Meyers Manx
68 Country Buggy (KO 367)
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Smiley
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| posted on September 24th, 2011 at 03:12 PM |
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| Quote: | Originally
posted by SebastienPeek
Oh, and your wiring job, excellent in keeping in bloody tidy!
Looks awesome.
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Hahahahaha. You most be joking right?
It's horrible. I can't wait to tidy it up, cover it and get it clamped out of the way neatly.
Also going to add a plug at the firewall so I don't need to disconnect any wires to pull the engine, just unplug and drop on the ground.
| Quote: | Originally
posted by 11CAB
Good to see its getting close Fraser isnt far away
Josh turned 16 today and got to add this to his Baja......
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Sweet! Is she going to be all ready for Fraser? Are you going to Warwick next weekend?
And I love the plates, your son must be stoked. Wish I had a Baja that good at his age!
Smiley
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Anthiron
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| posted on September 24th, 2011 at 04:17 PM |
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This is looking great Smiley! I like what you have done with the exhaust. The wiring loom plug is a great idea. I might have to steal that one.
62/60 model bug eye baja bug, (Full Build in Progress)
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1979 Yamaha RX125 Two Stroke tracker project.
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OZ Towdster
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| posted on September 24th, 2011 at 06:28 PM |
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Looking good mate , r you staying down for the week between Warwick and Fraser or heading home between ?????
Don't let body work get in the way of real suspension travel
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SebastienPeek
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| posted on September 24th, 2011 at 06:33 PM |
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| Quote: | Originally
posted by Smiley
| Quote: | Originally
posted by SebastienPeek
Oh, and your wiring job, excellent in keeping in bloody tidy!
Looks awesome.
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Hahahahaha. You most be joking right?
It's horrible. I can't wait to tidy it up, cover it and get it clamped out of the way neatly.
Also going to add a plug at the firewall so I don't need to disconnect any wires to pull the engine, just unplug and drop on the ground.
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Definitely not joking, so much better than my setup that is for sure!
Yeah, that definitely sounds like a good plan. Will make removing an engine from a baja even easier! :P
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Smiley
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| posted on September 24th, 2011 at 06:48 PM |
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| Quote: | Originally
posted by OZ Towdster
Looking good mate , r you staying down for the week between Warwick and Fraser or heading home between ?????
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Unfortunately I don't have enough holidays so I have to go home for the week. Are people from the Manx Club meeting up on Friday morning again and
cruising down? Dad and I are driving down Thursday night and if we time it right we can meet up with you guys and join the convoy.
Smiley
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Smiley
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| posted on September 24th, 2011 at 09:32 PM |
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| Quote: | Originally
posted by Smiley
Things still left to be done.
Make new filter mount.
Put oil in transaxle and engine.
Connect shifter coupler to gearbox.
Bleed brakes.
Install and adjust handbrake.
Plug holes in manifolds.
Add proper spacers under axle nuts.
Modify muffler to fit.
Mount coil to firewall.
Fit leads and engine wiring.
etc etc etc etc.
What have I missed? Any more ideas?
Smiley
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All done!
If you said I was a Volkswagen man, you'd be right.
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Smiley
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| posted on September 25th, 2011 at 09:03 PM |
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Ok!!
What a weekend it's been.
Car is done and running. I've driven it. And my first comment it HOLY POWER BATMAN!!!! It is a hoot to drive!
My second thoughts are, the handling is sensational. A million times better than the swinger. The IRS conversion should have been done when I built
the car. It no longer wobbles around like a duck wagging it's tail when I hit bumps on the road. So long swing axle!!
I spent a while yesterday finishing off all the jobs on my list. Adjusted and bled brakes, put oil in the gearbox, swapped the right spacers under the
axle nuts, etc etc. Lots of little jobs.
One issues I did have was that I could only get 3rd and 4th gear after I connected up the shifter coupling.
I traced this problem to the dimple in the gear selector shaft. Because the box is out of a type 3 the dimple in the shaft is on the underside. Guy
that gave my the box redrilled the dimple on the top side for use in a beetle.
Problem was the dimple was a mm or 2 out of the right spot. Even this tiny amount completely stuffed the shifter adjustments. All I did was flip the
coupler over and screw the set screw into the factory dimple. Was a little tight to get my hands in there but we got there in the end. I get all the
gears perfectly now.
I also have this awkward situation.
Haven't even driven her yet and she's leaking oil in true Volkswagen style! I have few small weeps from some of the fittings. Nothing major, I'll
fix them on the next oil change.
I do have one oil leak that is a little more annoying. Seems that the oil cooler is leaking. Not sure if it's seals or the cooler itself, I haven't
had the fanhousing off yet. The seals are new so I'm thinking the cooler might be buggered. Good excuse to buy a new one? It's leaking a little oil
into the fanhousing, which the fan is doing a fantastic job of distributing from one end of the engine to the other. Needs a wash now. I think I'll order a brand new cooler and swap
it straight on. Fins that aren't bend over or full of rocks are going to help the cooling anyway.
Smiley
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Smiley
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| posted on September 25th, 2011 at 09:22 PM |
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While tuning yesterday things didn't seem quite right. So I got some spray out and sprayed around the carbies. Sure enough one of them seems to have
a vacuum leak. I pulled it off the car and it was leaking from this gasket here.
The things are brand new!!! I pulled it apart and added a tiny smear of gasket maker to both sides of the leaking gasket. Put it all back together and
Bob's your uncle. I pulled the other side off and did it too just in case.
Other than that the carbies seemed to tune up quite well. Still needs some fine tuning but we'll get there. I think it's running quite rich at idle.
I drove down the Gladstone today, 300km round trip. Before I left to come back I stopped at Red Rooster drive through to get some lunch, was sitting
there probably 5-10 minutes with the car idling. When I left and was driving though town the car was missing and backfiring. I think I fouled the
plugs up. Got her out on the highway and it wasn't long before the plugs cleaned out and she was running sweet again. Same thing happened as I was
driving through Rockhampton, just from stopping at the lights. Must be running quite rich to do this so quickly.
Aside from that the car drove very well today. Oil temp sat between 75 and 85°C and oil pressure remained constant with no issues. Fuel consumption
is around 10L per 100km. I'm sure this will get better when I sort the tune out and get everything running perfectly.
Smiley
If you said I was a Volkswagen man, you'd be right.
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