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 hellbugged
A.k.a.: Daimo Pell
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48's and straight cuts
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| posted on January 1st, 2012 at 01:32 PM |
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started the year by letting the lil screamer eat Dorrigo mountain for breakfast 
stormed it's way up the 17km of winding road, 5 speed providing awsome ability to keep it in the tourque so not needing to rev the ring out of it.
engine temps stable around the 100 degrees at the top of the hill
brakes performing well on the descent............then back down the 110 zone to home in 5th. love it!
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hellbugged
A.k.a.: Daimo Pell
23 Windows of Awesome
48's and straight cuts
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| posted on January 3rd, 2012 at 05:30 PM |
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Out and about flippin some gears....
http://www.youtube.com/watch?v=343FPopS63c
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vassy66T1
A.k.a.: Marcus Vass
Veteran Volks Folk
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| posted on January 3rd, 2012 at 05:42 PM |
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Looking real sweet Mr Pell
A 1776cc was the first VW engine I had. Still have a soft spot for it.
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STIDUB
Custom Title Time!
Over it.
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| posted on January 3rd, 2012 at 07:49 PM |
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Volkswagen Drivers Club of Queensland - member 
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less |
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Dasdubber
A.k.a.: Alan Agyik
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DAS Resto Haus
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| posted on January 3rd, 2012 at 07:59 PM |
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Nice one mate - can't wait to see it at valla and hear the little screamer in person!
Al
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 matberry
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| posted on January 4th, 2012 at 11:53 AM |
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Sweet as Daimo, nice to be cruising eh....
More vids, share the symphony dude.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
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1303Steve
A.k.a.: Steve Carter
Scirocco Rare
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| posted on January 4th, 2012 at 06:13 PM |
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Hi Daimo
Nice noises, do you still run the GB 309? The gear ratio selection looks spot on. Boy those back roads look rough.
Steve
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hellbugged
A.k.a.: Daimo Pell
23 Windows of Awesome
48's and straight cuts
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| posted on January 4th, 2012 at 08:38 PM |
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Hi Steve,
yep GB 309/Engle V26 and yes also on the rough roads, that's actually a loop of the old highway!!..........will do another vid up Dorrigo, it's much
smoother 
Heya Marcus, hope your's is coming along too!
Will do Matty, make's bluey sound quiet hey!
Al, just take it for a blab to hear it in person......have you had any time for your rides of late?
Dave......what can i say........ driven, not wishen! 
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JVLRacing
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| posted on January 5th, 2012 at 07:25 AM |
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 nice work mate
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matberry
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| posted on January 5th, 2012 at 08:59 AM |
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| Quote: | Originally
posted by hellbugged
Will do Matty, make's bluey sound quiet hey!
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Mate, she sounds soooo sweet and smoooooth, not to mention those beautiful ratio's.....mmmmmmmmm
Bluey has a harshness coming through the chassis, it's the crank and rods trying to get away from the IDA's .....but I won't let em !!!!!
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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rose
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doin it for d girls
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| posted on January 5th, 2012 at 12:27 PM |
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sounds great love it, makes me want to go get the bug out the shed and go for a cruise
[img][/img]
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on April 14th, 2012 at 09:26 PM |
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Daimo's Berg 5
This box was originally built in the USA.
Just before the VWMA Showdown,
Daimo called me to say he heard some noises coming from his Berg-5.
With a few upgrades in mind, now was the perfect opportunity to pull it out (and slot in a trusty 40hp box) before any further damage was done.
Most of the problems were from a lack of oil flow to the axle spades.
This occurs after long periods at highway speeds, because the superdiff , with its extra casting, reduces oil flow to the side gears and axle
spades.
Daimo scored a ZF diff off thesamba for the right price, and we also decided to change 4th gear to a 1.2174 ratio from the 1.3182. Now was the perfect
time to do those changes.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on April 14th, 2012 at 09:31 PM |
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I sourced some new fulcrum plates, and repaired the axle spade until Daimo can source some new axles.
Among the normal maintenence issues, the third gear needle bearing had collapsed.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 09:38 PM |
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While the ZF looked a little rough when it arrived, it was actually a real gem.
With just a little tidying, and some slight machining to restore the factory torque settings, it came up beautifully.
Also replaced this time around, was the pinion bearing,
diff bearings,
and pinion depth and backlash re-set for these new bearings.
The company that originally built this trans in the USA do not always replace these parts in a new trans.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 09:44 PM |
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Also of note was the shift rail slots were uneven.
Being hardened steel, a tungsten end mill was required
to make this rail closer to the other three.
Then the hockey stick was welded and reshaped to tighten up the tolerance,
for a more precise shift quality.
A later input shaft was sourced, which uses a wider seal surface.
...and a new seal:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 09:49 PM |
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Chrome Moly pinion bearing retainer:
New genuine synchro for first gear.
This one was the last of my NOS. These are NLA now.
Added some oil holes in the 1st/2nd hub,
and reduced the end float back to a more reasonable clearance.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 09:56 PM |
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To improve the oiling problem,
VW issued a service bulletin that showed a modification to the side covers.
It was meant as an upgrade for the ZF diff, but should work well for super diff installs as well.
This lets oil out to the spades, even after long periods at speed.
Third gear got a new synchro also, and the hub for 3rd and 4th also got the oil hole treatment,
and some machining to equalize the end play.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 09:59 PM |
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Here is the new 1.2174 fourth gear and hardened key.
welded hub;
NEW SYNCHRO:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 10:01 PM |
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Assembled gear stack of first through 4th gear:
Berg 5 housing:
Kept the 0.821 5th gear:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 14th, 2012 at 10:04 PM |
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Into the jig to adjust the shift forks:
Then into the Rhino case:
| Quote: | Originally
posted by westi
That's mad Alan.
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SebastienPeek
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| posted on April 14th, 2012 at 10:23 PM |
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Wow, what excellent work Dave!
The Berg5 looks amazing, well worth the cash it seems!
Sounds smooth as well, in the old video, want to see a new one with the latest changes to the Berg5 as soon as possible that's for sure!
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mactaylor
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| posted on April 15th, 2012 at 07:59 AM |
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very nice dave whats the part number on that syncro that is NLA? got a mate with a fair bit of tansmision NOS. will check next time im out there.
EVERLAST CONCRETE TANKS
1800 552 123
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hellbugged
A.k.a.: Daimo Pell
23 Windows of Awesome
48's and straight cuts
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| posted on April 15th, 2012 at 07:59 AM |
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I think the word is "Salubrious"
Brilliant D.B, nice to have it set up by a true SPECIALIST.....awsome attention to the little things as per your norm
We are lucky to have you, appreciate it heaps
happen to have any pics of the diff internals?
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on April 15th, 2012 at 08:45 AM |
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| Quote: | Originally
posted by mactaylor
very nice dave whats the part number on that syncro that is NLA? got a mate with a fair bit of tansmision NOS. will check next time im out there.
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113 311 269 1 is the one I have been using for first and second gears.
the "1" is the part I use, there are a few other suffixes also.
113 311 295 for 3rd and 4th.
It can have various suffix letter or numbers too.
Genuine only please!!
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
Posts: 5901
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Registered: January 6th, 2005
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| posted on April 15th, 2012 at 08:46 AM |
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| Quote: | Originally
posted by hellbugged
I think the word is "Salubrious"
Brilliant D.B, nice to have it set up by a true SPECIALIST.....awsome attention to the little things as per your norm
We are lucky to have you, appreciate it heaps
happen to have any pics of the diff internals?
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Sorry daimo, forgot all about pictures,untill i began the final assembly of the trans.
| Quote: | Originally
posted by westi
That's mad Alan.
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matberry
Super Moderator
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| posted on April 15th, 2012 at 10:53 AM |
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Noice
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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vassy66T1
A.k.a.: Marcus Vass
Veteran Volks Folk
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| posted on April 15th, 2012 at 05:28 PM |
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I'm green with envy ...
Your work is fantastic DB.
Sounds like it is going to shift very nicely.
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coletrickle
Wolfsburg Wizard
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| posted on April 15th, 2012 at 05:59 PM |
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| Quote: | Originally
posted by vassy66T1
I'm green with envy ...
Your work is fantastic DB.
Sounds like it is going to shift very nicely.
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For sure it will be the best shifting 5 speed around!4 speeds that's another question
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JVLRacing
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| posted on April 15th, 2012 at 06:40 PM |
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the popcorn sure taste nice....
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matberry
Super Moderator
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| posted on April 15th, 2012 at 07:02 PM |
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| Quote: | Originally
posted by vassy66T1
Sounds like it is going to shift very nicely.
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It was nice before....can only be better, must nearly shift with mind control
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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