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 JVLRacing
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| posted on July 10th, 2008 at 08:50 PM |
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| Quote: | Originally
posted by 2443TT
Since you asked... and also because tomorrow I need to show the engineer that the steering works and doesnt foul on anything... here is one side of
the car assembled. I've also dropped the front end to its lowest level. This is 100mm from the chassis framehead to the ground, the guards are
125mm at their lowest point to the ground. Im pretty happy with how its looking. Its looking insane, which is what I was hoping for. The back is
still stitting a little high as there is no engine in there. The idea is to get a little of the tyre up inside the guard (which is why they are a
little wider than they need to be, to allow the car to get lower to the ground while still having 2-2.5" suspension travel.
Still finishing the left rear guard, and i need to tidy the ends where the rolled edges are on the rears and the fronts a little more. Ive gotten
them very close to flat without using any bog so far. Its been raining the past 2 days so i havent been able to take the guards outside to sand. Ive
been trying to limit how much dust I get over everything inside the workshop...(it hasnt worked).
Cheers,
Ian
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nothing wrong with that mmmm
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2443TT
A.k.a.: Ian
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| posted on July 10th, 2008 at 09:02 PM |
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Well the ball is definatly rolling down hill now. This afternoon I finished the last of the body to chassis mounts. Boy was that fun because no
matter how much you sweep a concrete floor it always seems to retain some fiberglass dust Then I stripped the car back to nearly nothing again, body
off the pan, and am stripping back the chassis at the moment.
This tomorrow and this weekend I'll be finishing the chassis off completely so it can be sand blasted and painted next week and the final assembly
can begin. All that remains to be done on the chassis is front and rear sway bar mounts, seat belt mounts and some minor corrections to the front
suspension alignment.
Im going to enjoy doing something with metal again, im sick of that fiberglass crap.
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Flintstones
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| posted on July 10th, 2008 at 09:12 PM |
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Great to here it passed engineering!!!
Cheers
Dino
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2443TT
A.k.a.: Ian
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| posted on July 13th, 2008 at 09:23 PM |
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Hi all,
Well this weekend I went hard at it and the chassis is now within a few hours of being finished. The front swaybar mounts are finished. I added a
triangle into the front suspension mount with some 5mm plate which strengthens the suspension mount and also allowed me to dril and tap some 12mm
threads to mount the swaybar too. The back is done simular with mounts welded to the rear torsion housing which are also drilled and tapped with 12mm
threads.
Ive also added a little more 5mm plate to the floor pan in front of the torsion housing at the outside to serve as the base for the roll cage mounts
and seatbelt mounts. Last of all I went to town on fully welding the outer edges of the floor pan from the under side where the 40mm plate joins the
20x20 angle.
The chassis is now fully stripped of all parts and ive put bolts in everywhere there is a thread so I can have the chassis sand blasted and painted
next. Ive also added some industrial casters to it so its easy to wheel around. As for the weight, i estimate the front weighs around 70kg and the
back about 60. With it stripped i can easily pickup the chassis and move it around, so it will be very intestesting to see what a corner weight is
when its assembled.
All that remains now is to go over it with a flapper disk and remove as much splatter as I can from it so it will look nice an clean when its painted
and the final assmebly begins. Sand blasting and priming this week, then paintin on the weekend when i convert my second garage into a spray booth.
 !!!
Here are the pics.
Cheers,
Ian
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Dasdubber
A.k.a.: Alan Agyik
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| posted on July 13th, 2008 at 09:30 PM |
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Two garages....now thats just being greedy Ian! 
Nice progress by the way, I bet you are looking forward to painting the chassis - obviously it is a very well thought-out project so hopefully there
will be no "Doh - wish I welded that there before I bloody painted it!"
All the best
Al
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2443TT
A.k.a.: Ian
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| posted on July 13th, 2008 at 09:45 PM |
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| Quote: | Originally
posted by Dasdubber
Two garages....now thats just being greedy Ian!
Nice progress by the way, I bet you are looking forward to painting the chassis - obviously it is a very well thought-out project so hopefully there
will be no "Doh - wish I welded that there before I bloody painted it!"
All the best
Al
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Yes indeed it is very handy having the 2nd garage. I park the gtr in there for the moment so it doesnt get covered in dust from all the work ive been
doing on the vw lately.
Yes I am getting very psyched about doing the assembly soon. I am hoping i won't have any of those "dam i should have welded that in moments"...
thats what the trial fitting to the chassis was for... hopefully that was enough. Its all going to be done in 2pack so it should be possible to touch
up if necessary though.
I might start a debate on what colours to paint it all too.
I am going to re-spray the shell and guards at some stage, most likely a dark metalic grey like Ive seen on the porsche 997's but initially im just
going to have the guards done in arctic silver. The interior current has black and grey seats, silver autometer gauges and a lot of carbon fibre
trim. I am going to keep that theme on the outside too with some custom carbon running boards/side skirts and the engine lid.
As for the chassis I am thinking a medium grey hammertone, or just a plain medium grey. The 1mm alloy floor pan sections can be done in another
colour, or the same as the chassis. They will be screwed and sikaflexed to the chassis from the underside.
Alloy suspension parts will be etch primed and painted light grey. Shocks will remain green. Spindles, steering rack and swaybar mounts will be
black.
I'll be doing the brake rotor centers light grey same as the suspension parts, and the calipers will be detailed but painted black again (everyone
has red calipers).
All feel free to jump in with suggestions.
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Dasdubber
A.k.a.: Alan Agyik
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| posted on July 13th, 2008 at 10:13 PM |
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| Quote: | Originally
posted by 2443TT
I might start a debate on what colours to paint it all too.
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We all know what colour Pete and westi would choose 
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 matberry
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Go hard or go home
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| posted on July 14th, 2008 at 10:01 PM |
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| Quote: | Originally
posted by Dasdubber
| Quote: | Originally
posted by 2443TT
I might start a debate on what colours to paint it all too.
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We all know what colour Pete and westi would choose
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PINK bits
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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Brad
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| posted on July 14th, 2008 at 10:04 PM |
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Any ideas on how much it will weigh ?
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2443TT
A.k.a.: Ian
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| posted on July 14th, 2008 at 10:09 PM |
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Not sure... its got to be pretty close to a factory pan though. This evening I cleaned up the weld splatter with a flapper disc and then end for end
flipped it to tip out all the dust and crap from the tunnel. It wasnt easy but I managed (im not a big guy... about 68kg). Time will tell... i'll
know in a few weeks and will weight it as a bare chassis for comparison to westi's build. Westi's posted corner weights of his chassis in his
thread from memory....
Saw the sand blasters today... Its off to be blasted and painted tomorrow morning!!!
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Golde60
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| posted on July 15th, 2008 at 03:48 AM |
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| Quote: | Originally
posted by Golde60
I want to see just how mean that car looks once those W I D E guards go on
Function over form, its gonna look mean alright.
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WOW
thats WWWWIIIIIIIIIIIIDDDDDDDEEEEEEE
I like it.
I think I underestimated what the finished product would look like, but I am impressed.....
Can t wait to see and hear it run
When does the case arrive from Rocky?
...................( O \ l / O ).....................
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Golde60
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| posted on July 15th, 2008 at 03:54 AM |
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best of luck with the painting Ian
As for the chassis and pan, I m voting for them being the same colour - black......
...................( O \ l / O ).....................
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2443TT
A.k.a.: Ian
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| posted on July 24th, 2008 at 02:26 PM |
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Woo Hoo! Picked up the chassis from the sand blasters today. No assmebly this weekend though as im off to melbourne for a 2 days training on tuning
the Wolf ECU, since ive just recently become the Cairns distributor for Wolf ecu's and will soon be listed as an authorised tuner.
Pic...
The Rocky Jennings engine case should arrive tomorrow. Paid GST on it yesterday and it left sydney by air last night.
Detailing and chassis assemby starts next week.
Cheers,
Ian
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reub
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| posted on July 24th, 2008 at 03:42 PM |
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Looks like a nicely evolved volksie chassis there dude! Nice work...
Reub
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LIFE IN THE LOW LANE
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| posted on July 24th, 2008 at 03:55 PM |
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Looks the real deal now with nice glossy paint Ian!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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VWFREAK
A.k.a.: Peter / Bones
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| posted on July 24th, 2008 at 04:04 PM |
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Crazy stuff Ian, keep it coming.
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Mick058
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| posted on July 25th, 2008 at 08:23 AM |
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beautiful, thanks for posting...it's been sad not seeing your daily progress as you waited for the chassis.
It's like missing out on the morning coffee. 
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2443TT
A.k.a.: Ian
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| posted on July 28th, 2008 at 02:16 PM |
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Hi Guys,
Melbourne was too bloody cold yesterday, but the Wolf EFI training was awesome. Ive learnt heaps about the new V5's ecu's capabilities, all i need
to do is finish a car so I can apply some of these things ive learned to what Im building.
Today I collected the new engine block fresh from Rocky Jenning's workshop. It looks great. Its a 2.1 block, water jackets removed, raceware main
stud kit which torque to 40ft-lb, barrel shimms for 94mm cylinders, machined offset stud inserts for 94mm bores, the case is internally clearanced for
the 88mm crank and has a custom bearing set to suit my 88mm flanged crank and this case, and last of all sleaved lifter bores. I expect i'll be
doing a trial assembly inside a month, however the main focus for me is still to finish the chassis.
I purchased the paint to detail all the chassis components today, and the remaining parts (new steering rack ends, tie rods etc) are waiting at the
postoffice for me to collect tomorrow. Prep for painting and detailing starts tonight!
Cheers,
Ian
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trickysimon
A.k.a.: Simon Azzopardi
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| posted on July 28th, 2008 at 05:15 PM |
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Don't know anything about these engines. What are the 3 grooves under the identification stamp down the bottom for?
Simon
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hellbugged
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| posted on July 28th, 2008 at 06:07 PM |
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nice one Ian, can't wait to see more.........mmmmmm oxyboxer
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66deluxe
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| posted on July 29th, 2008 at 03:38 PM |
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| Quote: | Originally
posted by hellbugged
nice one Ian, can't wait to see more.........mmmmmm oxyboxer
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Oxyboxer, my dream engine.
This is my Volkswagen, there are many like it, but this one is mine. Without me my Volkswagen is useless, without my Volkswagen, I am useless.
61 Karmann Ghia 2110cc type1 w Los Panchito's
66 Deluxe Beetle 2270 type 4
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silver
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| posted on July 29th, 2008 at 04:19 PM |
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| Quote: | Originally
posted by trickysimon
Don't know anything about these engines. What are the 3 grooves under the identification stamp down the bottom for?
Simon
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clearance for case stud access
Keeping it real !
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2443TT
A.k.a.: Ian
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| posted on July 29th, 2008 at 07:41 PM |
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Ok guys brace yourselves... final assembly has begun.
Tomorrow im painting the rear end parts, and putting in the steering rack which is painted now but still drying.
Cheers,
Ian
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
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| posted on July 29th, 2008 at 07:51 PM |
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mmm very noice!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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reub
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| posted on July 29th, 2008 at 07:55 PM |
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I'm getting v e r y excited dude...
Reub
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Flintstones
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| posted on July 29th, 2008 at 08:49 PM |
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it's looking the business!!
Cheers
Dino
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volkdent
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| posted on July 30th, 2008 at 01:54 AM |
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How much, if any, did you have to cut out of the body around the front end of the front control arms? I looked at doing this years ago and as I
remember it needed to have a decent amount cut out of the rear of the spare tire well. If you had to cut, can you snap a couple of pics?
Jason
If I could just get paid for my sleepless nights....
2008 BMW 335i
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2443TT
A.k.a.: Ian
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| posted on July 30th, 2008 at 08:40 AM |
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I didnt have to cut any material from the front or the rear to clear the suspension. The mcpherson strut front end clears the body by about 5mm each
side. I did however remove a fair amount of the rear inner guards to make room for the much wider than stock engine, and to make the rear apron
removable.
This suspension setup has been made possible due to the wider chassis (rotor to rotor) that the later model 944s/968's have. They wheels have small
offsets. The early 944's are much narrower rotor to rotor, and use large offset wheels instead.
In my case I have not wanted to keep the standard wheel track. The chassis is 200mm wider overall than a standard bug, making it the same as the
944's. This means all my steering angles will be the same as the 944. Only bump steer will be slightly different as the steering rack sits slightly
higher (about 10mm) than it would be on a 944. When the car is lowered to its limit that issue is solved.
In hindsight I really think the front and rear suspension from a r32 gtr skyline would have been a better way to go as far as handling is concerned.
Double A arms all around. But the front end would have gotten very complicated and as for steering geometry... the gtr is probably very diferent to
the VW or porsche 944.
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volkdent
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| posted on July 30th, 2008 at 10:04 AM |
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thanks for the reply. When you mate the body and pan again will you snap a pic of the area behind the spare tire well where it is near the front of
the control arms?
I think the KISS priciple is the best, and you've done a pretty good job with that. I went double wishbone myself, which is in itself complicated,
but very little cutting of the body or pan to offset that.
Look forward to a handling report!
Jason
If I could just get paid for my sleepless nights....
2008 BMW 335i
2001 BMW M3 'Vert
1998 BMW M3 Sedan
1960 VW Bug Bad Dub Racing |
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2443TT
A.k.a.: Ian
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| posted on July 30th, 2008 at 09:30 PM |
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Well today i installed the steering rack, all the hydraulic hard lines for the brakes and clutch. Then went to work sanding one of the rear trailing
arms and then painted it. Its time consuming doing all this work but I think its worth it in the end.
Here are the pics of today's progress.
Cheers,
Ian
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