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 Chr_
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| posted on March 12th, 2015 at 04:36 AM |
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Death by chocolate - My 1303 with a EJ25 Subaru engine
Hey everyone,
before I start, I want to thank you all for the useful information I got from this forum and all the other build-threads.
I've been reading your post for a long time and I think now it's time to tell my own story...
It all started almost 3 years ago when I decided to create something you can't buy at any car dealer. I always like the concept of an old car with a
lot of power nobody would expect...
Although many people (especially in this forum) have done such a project before, it's a totally different story when you try to do it yourself.
Today, we are almost done. I already did some short test drives, but we still have issues with the ECU and the engine is not running properly above
2.500 RPM.
However, here are the specs:
1303 super beetle from 1972
Subaru EJ25 SOHC from a 2000 Legacy
Adapter plate and exhaust system from LMB Technik
custom engine mount
Porsche 914 5-speed gearbox
228mm clutch from a VW T3 bus
Porsche 944 S2 brakes front and rear
Porsche 944 rear arms, driveshafts and front wheel hubs
Remmel Motorsports coil-over suspension front and rear
Cup-style struts
Heigo roll cage
So stay tuned and enjoy (hopefully)...
I'm sorry for the bad image quality, most of the pictures were taken with my smart phone...
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Chr_
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| posted on March 12th, 2015 at 04:42 AM |
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When we started disassembling the car, we found alot more rust than we expected ... but that's the same story with every project, isn't it?
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Chr_
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| posted on March 12th, 2015 at 04:45 AM |
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After the main welding work was done, we split the car in two...
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Chr_
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| posted on March 12th, 2015 at 04:48 AM |
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We had to replace one of the side panels and used the opportunity to fit a slotted front-end for the radiator...
After that, the chassis got sand blasted and repainted in black.
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Chr_
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| posted on March 12th, 2015 at 04:52 AM |
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This gave us time to gather some parts like the gearbox, brakes, driveshafts, adapter plate and so on...
When we got the chassis back, the fun part of the project began..
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Chr_
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| posted on March 12th, 2015 at 05:01 AM |
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We started to mount the gearbox, the rear arms, coil-overs and the struts.
We also test-fitted the engine with a reversed intake manifold.
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Chr_
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| posted on March 12th, 2015 at 05:05 AM |
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To fit the Porsche 944 handbrake mechanism to the beetle handbrake cables, we had to build some custom parts... looks somewhat sweet...
After that, we were able to mount the brakes and the exhaust system.
Rear-end was almost completed.
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karmann141
Wolfsburg Wizard
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| posted on March 12th, 2015 at 06:09 AM |
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Great stuff- more please 
1961 K Ghia - Porsche 5 sp, EJ20T, Brembo's, Dble A arm susp
1974 L Bug - Porsche 944 brakes, Boxster 16's
1974 Bay Camper - EJ20, twin radiators, Boxster 16x7's
Half Beetle trailer with Boxster 16x7's
2011 Tiguan TDI 4Motion
2010 LR Discovery 4 TDV
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1303Steve
A.k.a.: Steve Carter
Scirocco Rare
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| posted on March 12th, 2015 at 07:23 AM |
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great read more please
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Chr_
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| posted on March 12th, 2015 at 07:54 AM |
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After that it was time to get the chassis back on its wheels (at least the rear ones) and test-fit the body.
It didn't quite fit at that time, so we had to cut away some inner structure of the rear end and most of that piece of metal that is between the
engine and the gearbox.
The cat agreed...
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Chr_
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| posted on March 12th, 2015 at 07:59 AM |
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Some work on the radiator.
It's from an Alfa Romeo 33. The frame is custom-made.
I think Joel proposed it in one of his youtube videos. It fits perfectly and works like a charm, thanks for that!
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Chr_
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| posted on March 12th, 2015 at 08:01 AM |
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Some more custom Subi-related stuff.
We fitted the original Subaru fuel pump into the fuel tank of our beetle.
It is a very tight fit, but the spot seems to be really good since the inlet of the fuel pump should be very close to the lowest point of the tank.
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Chr_
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| posted on March 12th, 2015 at 08:05 AM |
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In the meantime, I prepared the front axle and brakes.
Check out my high-end sand-blasting ... yeah.... rain barrel and cardboard...
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Chr_
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| posted on March 12th, 2015 at 08:06 AM |
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Mounted everything to the car...
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Chr_
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| posted on March 12th, 2015 at 08:14 AM |
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Then it was time to the car back on its own wheels.
So now it's about 1.5 years since the start of the project.
These pictures were taken in February 2014.
The rims are Porsche Cup 7x16 with an offset of 55 front and 9x16 (70 offset) rear.
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benny_acko
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| posted on March 12th, 2015 at 08:55 AM |
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So good!Keep it coming...
1967 VW Beetle Deluxe
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 kombi_kid
Super Moderator
Good Kid too many projects
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| posted on March 12th, 2015 at 10:57 AM |
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very nice build! question about the manifold rotation did you just keep the injector wires to where they originally would of been or did you leave the
loom attached and rotate around?
cheers
rhys
it aint just cool its aircool'd
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retroresto
Wolfsburg Wizard
A.K.A Paul
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| posted on March 13th, 2015 at 02:37 PM |
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Nice work guy, Keep up the pics coming, I have a soft spot for 1303's!
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Joel
Scirocco Rare
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| posted on March 13th, 2015 at 05:25 PM |
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| Quote: | Originally
posted by Chr_
Some work on the radiator.
It's from an Alfa Romeo 33. The frame is custom-made.
I think Joel proposed it in one of his youtube videos. It fits perfectly and works like a charm, thanks for that!
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Glad it worked out for you, they fit like they are meant to be there.
Mine served me well even with an A/C condenser infront through many aussie summers, it's been replaced by a racing aluminium radiator now with a bash
plate for protection this time.
My cars seem to be roadkill magnets unfortunately.
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Doug Sweetman
Veteran Volks Folk
Nil Bastardo Carborundum
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| posted on March 13th, 2015 at 10:19 PM |
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Doubt there are many 1303's that see as many miles a yours too Joel.
Outstanding project !
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Chr_
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| posted on March 13th, 2015 at 10:30 PM |
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| Quote: | Originally
posted by kombi_kid
very nice build! question about the manifold rotation did you just keep the injector wires to where they originally would of been or did you leave the
loom attached and rotate around?
cheers
rhys
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Hey,
the loom remained in its original position, so injector wires, spark plug wires and everything is connected to the same cylinders as before.
I had to create a small sheet-metal adaptor for the iginition box to rotate it back 180 degrees so I could mount it in its original position on the
rotated intake.
The connection of all thoses hoses is another problem. Since I also rotated the coolant manifold, some hoses did fit as before, some other had to be
replaced with longer versions and routed across the manifold.
One more thing:
I had to use spacers between the engine block and the intake manifold
( http://www.rallysportdirect.com/GrimmSpeed-Phenolic-Thermal-Spacer-8mm-N-A-Su...)
to not collide with the rotated oil filler tube...
On the upside, I did not have to cut my firewall and the throttle cable can be mounted straight forward without any complex re-routing...
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SebastienPeek
Custom Title Time!
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| posted on March 16th, 2015 at 10:22 PM |
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The amount of want and desire to build something similar is back.
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Chr_
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| posted on March 25th, 2015 at 06:37 AM |
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Long time no beetle...
Sorry for delay, but here we go again:
We spent a lot of time to make everything fit.
Some minor and major body work, some additional holes here and there...
We had to do some work on the fenders, as well.
Front fenders are stock metal fenders, rear fenders are GRP +4cm on each side.
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Chr_
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| posted on March 25th, 2015 at 06:39 AM |
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Some more pictures on that topic...
Finally the car was ready to prepare it for paint.
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Chr_
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| posted on March 25th, 2015 at 06:43 AM |
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Some intermediate stuff:
Wrapped the exhaust and made custom engine mounts.
The engine mounts attach to the original holes of the rear bumper mount. The other side gets screwed to some custom brackets, holding the exhaust...
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Chr_
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| posted on March 25th, 2015 at 06:45 AM |
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After a few weeks of boredom, the car was finally ready for paint...
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Chr_
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| posted on March 25th, 2015 at 06:48 AM |
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That's it for now...
For those of you wondering why I named this thread "Death by chocolate...", here is a little teaser.
Stay tuned...
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karmann141
Wolfsburg Wizard
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| posted on March 25th, 2015 at 10:21 AM |
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Love your work - eagerly waiting the next installment. Thanks for the chocolate teaser.
What part of the world are you in by the way?
1961 K Ghia - Porsche 5 sp, EJ20T, Brembo's, Dble A arm susp
1974 L Bug - Porsche 944 brakes, Boxster 16's
1974 Bay Camper - EJ20, twin radiators, Boxster 16x7's
Half Beetle trailer with Boxster 16x7's
2011 Tiguan TDI 4Motion
2010 LR Discovery 4 TDV
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Joel
Scirocco Rare
Now containing 100% E-Wang
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| posted on March 25th, 2015 at 05:50 PM |
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That header is a work of art.
Is that a Porsche colour?
Wheeler dealers restored a 928 that was a very similar colour a few years back
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Aussie Dubbin
Fahrvergnugen
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| posted on March 25th, 2015 at 08:24 PM |
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I'd be wrapped with those headers
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