| [ Total Views: 25622 | Total Replies: 315 | Thread Id: 102601 ] |
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 vduboy
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| posted on March 23rd, 2014 at 05:23 PM |
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Finished off a heap of little things this weekend that have been bugging me, finished making the front and rear seat belt mounts, bolted up the rear
seats, fit the exhaust properly, trimmed off the outlet and made a new one to go past the rear bar still have to trim this a bit more. Got my fuse box
and relay holders as well, have got my wiring diagram drawn up, just need to check lengths and figure out which colour scheme I will use for the
wiring, I have a mix of vw, honda suzuki yamaha and gasgas colours all rattling around in my head!
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vduboy
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| posted on March 23rd, 2014 at 05:30 PM |
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More pics, fuse box and relay mounts, seat belts all in, and the tailpipe extension.
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vduboy
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| posted on March 23rd, 2014 at 05:32 PM |
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Anyone got some ideas about how I could fill these gaps on the dash assembly..? 
Was thinking over making the vinyl dash cover come down a little further? It is still in the mocked up stage at the moment, was thinking of making the
dash panel bigger to make it easier to fit my gauges neatly, although that will mean I have a bigger gap to fill..
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vduboy
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| posted on March 31st, 2014 at 09:33 PM |
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Got a few more niggly jobs done this weekend, made the bracket for me remote oil filter, Tried to remove the exhaust studs to install longer ones,
only one wanted to come out so I decided to stop there and not have to pull the head to drill out a broken stud.
I ended using some stepped nuts to use the whole stud and not just the last three threads to mount the bracket,
still need to sort out some decent lines and fittings for this,
Got my wiring diagram roughly drawn up, enough to at least get my colour codes and number of colours sorted, ordered all the wiring heatshrink and
terminals today.
Am still trying to decide where to put the battery, I am trying to get a smaller gel style or glass mat battery. I don't want it up the front, was
either going to put it in the standard spot under the rear seat, although was trying to save this for a hidden speaker location, or make up a bracket
and box it in above the gearbox.. any suggestions?
I could even cut a hole in the rear parcel tray area and make a lid/box there?
Also started mocking up the dash, looks like I will have to make a bigger dash panel to neatly fit my gauges and idiot light pod. I thought i had a
good location for it all then fit up the switchgear and it covered the idiot lights perfectly... 
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vduboy
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| posted on March 31st, 2014 at 09:38 PM |
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Does any one have the size of a battery of a ej22 on hand? Since that is the starter I have installed and I figure my motor will have less compression
than a ej22.
What are your opinions on the best routing for the oil lines? I can swing them over the top then underneath the header, probably heat wrap them so
they don't get toasty,
Or go down between the filter and motor depending on whether or not I can get fittings to do a 180 turn then to the pump?
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vduboy
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| posted on March 31st, 2014 at 09:48 PM |
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Anyone know the proper filter that is supposed to go on these? I believe it was supposed to be for high pressure? The motor in the old car used to get
450kpa when revved when the oil was cold!I got some side blinkers for the buggy but still not sure if I can get away with not having them, I think
they ruin the lines a little.
Bought these Narva ones but didn't like them so got some bike ones that are very flat, and e marked.
I have two spots to put them unsure which placement I like better.
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vduboy
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| posted on April 6th, 2014 at 07:06 PM |
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Got a bit more of the dash done today, dummied up my gauges, realized i'd have to make a bigger panel to fit them in neatly, so without a fancy pants
plasma cutter I had to do it the old fashioned way hole saws files and die grinders! Turned out quite well I think. Stuffed up the speedo hole by
using a 102mm hole saw when the speedo is 100mm. I thought it would ha a little leeway but was too loose for my liking so made up a small ring around
the speedo to fill the gap.
Also made a bracket to lift the left hand side of the lower dash tub as mine was a little saggy. Fitted up the hinge to the glove box lid. Then fit
the lock to the other mis-supplied glove box lid. That was my dumdum moment for the day!
The wiring supplies should be here this week but I'm off playing dirt bikes for the weekend so Ill have to get stuck in next weekend.
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vduboy
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| posted on April 6th, 2014 at 07:08 PM |
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More piccys
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nils
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| posted on April 6th, 2014 at 08:26 PM |
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Neat 
Quit calling rust patina
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vduboy
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| posted on April 6th, 2014 at 08:50 PM |
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Cheers mate.
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vduboy
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| posted on April 13th, 2014 at 08:53 PM |
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My ride got canned so I made a start on the wiring, had to finish up a few loose ends on the motor first, got a K&N oil filter for the motor that
can handle the high oil pressure on cold starts, but the bastard is the biggest filter I have seen! So I had to remake my filter mount bracket, little
chop and weld and it now clears the bar work. Gave me a chance to get some more alloy welding practice in. Got some hi temp hi pressure oil lines as
well, these are still to be heat wrapped to protect the from the exhaust. These are only temporary until I figure out how to decipher those bloody AN
fittings that everyone uses...
Also gave the tank a good flush out and a sand and primer and threw some paint at it too. Had to clean up the corners of the tank so it would fit in
the recess. I almost couldn't resist the temptation to hit the corners with the angle grinder but then somebody else would have to finish it for me!
So out with the tin snips and a file and gave the tank four nice round corners.
Started laying out all my wires for length marking down the colours as I went so I didn't have to try and remember them. Got one side heatshrunk and
pulled into the 32 mm conduit. Was probably overkill having two of them either side but at least I have space for more later on. Left a extra wire in
there as well incase I need to add pull more through at a later stage, or when I figure out what I've forgotten.
Also got a set of later curved windscreen wiper mechanisms as per Ben's recommendation. These will sweep much more area than the standard 1500 ones.
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vduboy
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| posted on April 13th, 2014 at 08:55 PM |
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Here's a pic of the new battery I got from work, cranks the motor way quicker than the stock one did. Big thanks to Paul from Steelart too, that is
the first time I've had a chance to try out his Cranky-kit, The old Vw starter needed two batteries to turn it over where now it only needs one. I am
stoked!
This is what I had to do to make the oil filter fit
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vduboy
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| posted on April 13th, 2014 at 08:57 PM |
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Couple more pics of the conduit into the lower dash tub. Will silicone when it is all in place.
Here is the fuel tank painted, pretty sure I will need to shorten the filler neck to clear the bonnet. Had to buy a new fuel sender, the one out of
the donor car was rooted. Hope it works with the Vdo gauge..
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vduboy
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| posted on April 13th, 2014 at 09:00 PM |
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One side of the wiring done, taped it on to another wire to pull in through the conduit.
Other side waiting for heatshrink, Finished instrument panel in place.
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tayloredvw
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| posted on April 14th, 2014 at 07:30 AM |
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What kind of oil filter did you end up getting? Is it specifically a high pressure one?
Looking good by the way.
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vduboy
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| posted on April 14th, 2014 at 07:42 AM |
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| Quote: | Originally
posted by tayloredvw
What kind of oil filter did you end up getting? Is it specifically a high pressure one?
Looking good by the way.
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From what I read on their site it is, It is a HP 3001 K&N. Thanks mate!
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vduboy
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| posted on April 21st, 2014 at 08:20 PM |
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So was up to my eyeballs in wiring this weekend, it's very slow going and tedious. Got the motor/starting circuits and all the rear lights hooked up
at the back and the right hand harness heat shrinked and pulled into place. Haven't been able to find a wiring diagram anywhere that matches the
colours/plug of my subaru steering column so have been going through everything with a meter to figure out what's what. WTF is it with subaru's idea
of switching the earth on everything?? Bloody weirdo's.. Still haven't sorted out where speakers etc are going.. ill leave that for later!
Was figuring out the wires on the ignition switch and couldn't get a good reading of most of them so pulled that apart and the contacts were toasty
as... I will catch a break soon! Hahaha, so repaired them for now, there was actually a spare terminal that I repurposed instead of the toasty
one..
I popped a few more holes next to the rear brake line for the starter motor leads as it was getting a bit busy there.
I also ran the negative lead straight to the starter motor's mounting bolt to get rid of the poxy original earth strap.
Here are some pics
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vduboy
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| posted on April 21st, 2014 at 08:23 PM |
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Got a battery box from work that my battery fits in, score! Got some rubber mounts for it mounted in the original spot under the rear seat, I wanted
it as close to the starter as I could. Made up a mount for the fusible links and the starter relay that attaches to the box as well.
These are some of the cable mounts I was talking about before, gives a nice neat spot to tie up too.
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vduboy
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| posted on April 21st, 2014 at 08:25 PM |
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My wiper motor frame off the donor car wasn't going to sweep enough area for my liking so went out and got a L-Bug one (big curved windscreen) this
looks like it will do the job much better. Still going to get rid of the Vw wiper motor and fit the subaru one to the Vw frame. Had to figure out an
easy way of getting the holes in the right spot for the wiper motor so I could start mocking up the fuse box etc, so traced around the windscreen
rubber and the left hand drive hole indents in the windscreen frame, flipped it over and transferred the mark to the other side. Got a few circuits
wired up and done, and haven't let any smoke out of the wires yet..
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vduboy
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| posted on April 27th, 2014 at 07:35 PM |
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So got some more wiring done, it was the wifey's birthday so I had to spend some time with her... some people are very selfish.. haha
Finished wiring the instruments, some muppet broke the windscreen earlier so I thought i'd remove it to make the wiring a bit easier, I would
recommend doing it before the windscreen frame is bolted in permanently. It made it a lot easier, also stopped me trying to reach through the
windscreen twenty thousand times..!
I used the angle bracket I removed from the glove box lid to mount the idiot lights, not sure why it was installed on the lid as it made the lid sit
out too far in my opinion. I'm sure it will become apparent later!
The idiot light console look very neat installed, the seat belt light runs off a signal wire from the alternator so once the motor starts charging it
goes out automatically after 15 seconds, only problem with that is my alternator light comes on at idle when the motor is cold (very low idle) so the
seat belt light comes on and off until the motor is warm. More of a annoyance than anything.
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vduboy
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| posted on April 27th, 2014 at 07:36 PM |
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Here is the hole I drilled for the lower wiring harness, (front blinkers, horn, brake light switch, and possibly the front washer bottle) it's almost
a bit of a guessing game where the drill will come out on the other side! Been pretty lucky so far.
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Boozo
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Back in the bug
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| posted on April 27th, 2014 at 10:19 PM |
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thats neat. where did you get the fuse box?
[size=4] '59 or Kombi?....feeling confused [/size]
'59 bug
'68 bug
'82 import T3 BUS. aircooled
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vduboy
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| posted on April 28th, 2014 at 06:04 AM |
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Thanks mate, from Repco it's a narva one I'll try and find the part number for you.
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vduboy
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| posted on April 30th, 2014 at 08:54 PM |
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| Quote: | Originally
posted by Boozo
thats neat. where did you get the fuse box?
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The part number for the fuse box is 54450BL.
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vduboy
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| posted on May 4th, 2014 at 07:22 PM |
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Got a little more wiring done today, Had to work yesterday, All the column switches are hooked up and working, headlight relays wired up, also wired
it up so the horn, hazards, brake lights and hi beam flash work anytime like a modern car just in case it has to be wired that way for ADR's. Only
have the two small front looms so finish up now, they are for the headlights indicators horn and side markers. Just waiting on a mate to get some
vinyl wrap for the last two and the wiring is done! Just need to find a spot for the front washer bottle too but think I might put that next to the
front left wheel well. Had a bad earth in the steering column possibly due to dirty steering column bearings? So bypassed that by using the unused
cruise control terminals, just repurposed one to use as a earth. Works good now. Started to tidy up the loom in the front still a bit to go, And a pic
running with lights!
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vduboy
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| posted on May 18th, 2014 at 07:11 PM |
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Got a few fiddly jobs that I have been avoiding done this weekend, sorted out my wiring for the subaru wiper motor, made a adapter arm to go between,
stripped the vw wiper arm frame, cleaned and re greased the spindles.
Plugged the motor in and ran it then parked it so I had a reference point to mount it to the frame.
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vduboy
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| posted on May 18th, 2014 at 07:14 PM |
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Gave it some paint and took the plunge and screwed it to the car. I had little paper pointers on the arms first just in case I stuffed up my angles
etc. Was a bit of a mission finding a good spot for the motor that cleared everything in use but also came out in one piece when removing it.
Luckily it is all good, sweeps a good range of the screen now. Heaps more than I could have managed with the 1500 arms.
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vduboy
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| posted on May 18th, 2014 at 07:19 PM |
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Made some blinker brackets up front out of some el cheapo motorbike headlight brackets and countersunk the mounting holes so it looks neat.
Dicked around for about an hour trying to find a spot for the washer bottle ended up settling for just in front of the beam in between the body in the
little recess for the steering box on the LH drive Manxters.
Extended my dash support bracket to also support the wiper motor.
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vduboy
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| posted on May 18th, 2014 at 07:22 PM |
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Cut down the fuel filler and tigged on a slight angle to get the fuel to run down into the tank and not over my wiring!
Also bought a LED no plate light and de cased it cut out a hole and mounted it nice and flush. I think I will have to space out the bottom of the
number plate to get the right amount of light on it.
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It will all be OK in the end, if it's not OK it's not the end!
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nils
Fahrvergnugen
Posts: 971
Threads: 65
Registered: January 11th, 2008
Member Is Offline
Location: central coast
Theme: UltimaBB Pro Blue ( Default )
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| posted on May 18th, 2014 at 07:46 PM |
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Great work, keep it up.
Quit calling rust patina
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