Weekend racer/ dragster project.

[tom'72]

A small introduction on my project which has been in the making for about 3 years now in total.

Started with a Standard bug with a 1600cc engine, engine blew up and I wanted something a bit beefier.
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_1.jpg

Bought a JDM EJ20TT engine with a Kennedy adaptor kit, flywheel and clutch
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820006_large.jpg

And a shortened sump from bug@5speed in Germany
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820032_medium.jpg

To get the engine to fit inside the body it had to be moved forward so I had to go IRS
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_18.jpg
(notice the fantastic yellow paint :) and the 944 brakes which I later ditched)

[tom'72]

Engine mated to the Pro street IRS tranny ( will swap for a G50 one day but not soon)
Käfer Cup Brace installed and put 18" BBS Le Mans (polished) on.
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_97.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820049_large.jpg

got a new front beam from CSP with adjusters welded in and reinforced it with these stainless steal parts, Red Koni shocks were also installed.
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_87.jpg

[tom'72]

Swapped the 944 brakes for a 996 GT3RS setup
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_162.jpg

http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_183.jpg

Also fitted a uniball setup in combination with adjustable AVO coilovers

Relocated the battery and put in a larger fuel tank with a return fule line
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_170.jpg

[tom'72]

On to the body mods:

Cut out the rear 1/4 to fit air scoops that feed the IC
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820196_medium.jpg

cleaned it all up a bit, some welding was required
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_138.jpg

http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_133.jpg

http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_139.jpg

Also fitted a ragtop kit for those summer drives
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820169_medium.jpg

[tom'72]

Interior mods so far:
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_164_full.jpg

http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_180.jpg

http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_181.jpg

sparco seats
http://memimage.cardomain.com/member_images/4/web/844000-844999/844382_116.jpg

[tom'72]

This is how far I am right now, shell is painted
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820206_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820205_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820203_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820204_medium.jpg

Will post pics of the the build up of the car soon.

[Wally]

All I can say is: WOW! :shocked:

Amazing clean build! Very well done. Love to see the intercooler location and the connection from the scoop towards it/them :rolleyes:

[Humble]

very well done! I can't wait to see this thing come together! Where did you mount the radiator? The dash looks very clean I dig the look of the blacked out gauges. The only thing you might regret is that steering wheel, it's gonna get mighty hot in the sun :)

[volkdent]

Tom you sneaky devil!!! All of this has been going on right under our noses and you didn't even give us a sneak peek!!!

Glad you finally filled is in, looks like it's going to be an awful lot of fun to play with. Are you sticking with the TT setup or are you going to convert to a single turbo? I too can't wait to see your intercooler setup, I'm just getting mine up to snuff now.

Jason

[NO_H2O]

Nice project. Bet you can't wait to get it on the road. :thumbup:

[wrenchnride247]

Great work so far! Get that project done, and post some video. :D

[evilC]

Great build up and high quality work.

(A point of caution though - the stainless steel beam braces will be subject to cyclic load, which stainless is not suited to as it fatigues quickly. I see that the mounting bolt is stainless also. The whole thing looks well engineered but it would be worthwhile keeping an eye on the chassis end as part of your general maintenance regime. Failure of that part should not be catastrophic as presumably the beam is still held with the standard bolting arrangement)

[Jim]

Very very good and clean job!!

With this engine in the back it might be kick some as...s in the road!!

[tom'72]

Thanks for the compliments but I couldn't have done it without wisdom and experience of the members on this site.

Where did you mount the radiator?

Made 2 strong brackets that are bolted on the front beam with the standard chassis bolts.

some pics:
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820207_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820208_medium.jpg

Made an aluminium schroud for the rad and an air ducts under de front that's powered by a linear actuator ( when the car will be standing still and the air ducts is closed it will be tucked away behind the front apron).

[Xellex]

wow verry nice build! The only thing I don't like is that steering wheel :p

[volkdent]

Made an aluminium schroud for the rad and an air ducts under de front that's powered by a linear actuator ( when the car will be standing still and the air ducts is closed it will be tucked away behind the front apron).

I had the same idea, but spring loaded. When the car is stopped the spring would pull it up, as you speed up the airflow causes pressure, it would pop down and scoop up more air. It's good because slow travel is where you expect to hit curbs and dips, not high speed.

Jason

[tom'72]

I had the same idea, but spring loaded. When the car is stopped the spring would pull it up, as you speed up the airflow causes pressure, it would pop down and scoop up more air. It's good because slow travel is where you expect to hit curbs and dips, not high speed.

Jason

That's a great idea, never thought of that.

The only thing I don't like is that steering wheel

it's not something you see on a bug often but it really got my attention on ebay and I figure it will fit nicely with all the other parts but if I don't like it or its not safe to drive it will be replaced.

[volkdent]

[QUOTE=tom'72;70324]That's a great idea, never thought of that.QUOTE]

I forgot to mention it would have stops, cable lengths(fine stainless steel), that would be the bottom throw. Without the stops the springs would just continue to stretch. I was thinking ABS sheet would be good as it would be able to handle the occasional beating and still be lightweight. The cables being flexible would allow for some sort of big shunt without breakage that a solid stop or your actuator would probably succumb to.

Jason

[excello]

I forgot to mention it would have stops, cable lengths(fine stainless steel), that would be the bottom throw. Without the stops the springs would just continue to stretch. I was thinking ABS sheet would be good as it would be able to handle the occasional beating and still be lightweight. The cables being flexible would allow for some sort of big shunt without breakage that a solid stop or your actuator would probably succumb to.

Jason

Hmmm. Thought about doing it the other way around so that it would be impact resistant with springs. So if you would hit a speed bump (lots of those in my neighborhood) or something like that, it would fold up and then pop open again. (bit tricky with the hinge placement, but could work) Would work as an indicator too, if you hear scraping then you have a few cm to go. With a stainless or titanium strip instead of all aluminum. But that opening at higher speeds is a really interesting idea...... Might use that idea instead, if you don't mind of course.

Sorry for the thread highjack....

[evilC]

This is what i like about this site - innovation and engineering. Keep it up Guys!

Clive

[volkdent]

Hmmm. Thought about doing it the other way around so that it would be impact resistant with springs. So if you would hit a speed bump (lots of those in my neighborhood) or something like that, it would fold up and then pop open again. (bit tricky with the hinge placement, but could work) Would work as an indicator too, if you hear scraping then you have a few cm to go. With a stainless or titanium strip instead of all aluminum. But that opening at higher speeds is a really interesting idea...... Might use that idea instead, if you don't mind of course.

Sorry for the thread highjack....

I think you might have missed the point of the springs, they would keep the scoop UP so you wouldn't hit speedbumps!!!:p

Then they would allow the scoop to drop down as air pressure forced the scoop open, then the cable stops would limit the complete travel to a predetermined drop.

Jason

[excello]

Haha, no I did get the point of the springs and all that. I was approaching the problem from another angle. Your system gives you a scoop when you need it because you get up to speed. (tom's too because he hits a switch) I was thinking I need a scoop, period. But trying to figuring out how to get it out of the way when I near a speed bump. I wanted to weld one on but then thought that might be a problem. I did think about linear actuators but thought it would be over-engineering and a pain to hit that switch every time I see a speed bump. I never thought about the fact that there are moments that I don't need a scoop, accept when it might get in the way. That's why I had a 'slap on the forehead' moment because I never thought of driving around slowly with a closed scoop. Yeah, I get bedazzled by my own 'creative' solutions sometimes so I don't see the simple problems anymore. It all does sound silly if you read it like this..... :idunno:

[Steve C]

Hi

I really love your car.

I made a really nice fixed alloy scoop for my old WBX bug, didn't last long so used what was left as a base and screwed a sacrificial plastic part in its place.

On the back of my radiator I copied what VW/Audi did on many water cooled cars, fitted rubber flaps on the back of the radiator.

At speed, forward air pressure pushes them away for more airflow over a wider surface, when the fan came on the flaps got sucked shut and the fan only sucked cool air in from the front of the radiator.

Steve

[tom'72]

Got a few friends together today and put the body back on the pan and the roll cage in. Rear end still needs to drop about 2 inches but will have to see how deep it will "squat" under accelleration first.

[NO_H2O]

Very nice. Slick and black. Got-a Love it.

[volkdent]

Amazing!!! Starting to remind me of Hugovw1976's monster!!!

http://img291.imageshack.us/img291/3316/2355855fv.jpg

Jason

[randyj]

Where did you get your roll cage?

Love your car!

Randy

[aircool]

Very nice car! the wheels look wicked. BBS LM's right?:cool:

[tom'72]

Bought the roll cage from a guy that had it as a spare way back in his garage, was pretty cheap, don't know hat brand it is.

Wheels are indeed BBS Le Mans.

[tom'72]

Got some more work done to it (most doesn't show in the pics)
Others news, picked up a Porsche G50 5-speed gearbox today that had already been mashined down (28MM off of the belhousing) so it's a bit shorter and easier to cram in the bug's chassis.


http://memimage.cardomain.com/ride_images/1/3378/2641/8443820212_large.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820211_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820213_medium.jpg

[excello]

I was really wondering how those side air scoops whould look like glued in after painting in stead of bondo'ing them in and then painting them. Turns out it looks really good. (just like the rest of the car) Love to see the car in person someday...

[tom'72]

Fitted the front hood for the first time today, it turned out very nice with the cf parts IMO.
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820216_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820215_medium.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820214_medium.jpg

Still have to wait 2-3 weeks to get the new front and rear windows+ rubber seals but all the wiring will keep me busy until then.

[Jim]

:eek::eek::eek::eek::eek::eek::eek:

it looks veeeeeeeeeery bad!!!

[tom'72]

Some new pics...

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820217_large.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820219_large.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820218_large.jpg

[ricola]

Niiice!

Maybe black out the door trim? Is that air scoop adjustable? Looks like a lot more ground clearance than earlier pics...

Rich

[chug_A_bug]

car PORN....:D
thank you
looks great


Chris.

[tom'72]

Niiice!

Maybe black out the door trim? Is that air scoop adjustable? Looks like a lot more ground clearance than earlier pics...

Rich

I like the shiny door trim how it is actually, it breaks the "blackness" of the car.

The air scoop is indeed adjustable, it's operated by a linear actuator.

[volkdent]

I like the shiny door trim how it is actually, it breaks the "blackness" of the car.

I'll go along with you there, but I'll have to add I might suggest adding the chrome to the rear windows as well, it does look a little uneven to me too.

Over all, just absolutely gorgeous, really mean. I may have missed this, but where did you get the CF hood from?

Jason

[72marinablue]

Have you thought about putting a spacer in the rear to get those LM's a little farther out?

[Wally]

Very nice Tom. She looks stunning!

[tom'72]

got the hood painted and mounted...
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820222_large.jpg

[johnnyvee]

nice CF:thumbup:

[Humble]

Oh wow, I really dig the painted CF decklid, awesome touch!

[tom'72]

Had some fuel issues, the Pierburg pump wouldn't do anything and was working fine when I started restoration.

turned out it had seized from sitting on the shelf for a few years but after some gentle pursuasion (tapping it with a big wreng a few times) it now works fine again.

Raised the rear by 1cm again so it fits the look of the front stance.

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820223_large.jpg

[euro1302s]

man this is nice!

[NO_H2O]

Looking very nice. I too love the balance of the exposed CF touches.

[kafercup]

Are those the Remmelle side scoops? Did you lip the quarter panels and set the scoops in (so they sit flush), or are they glued on top of the quarter panel with just the hole cut for the duct?

I have the same scoops and am trying to figure how I want to mount mine.

BTW, beautiful car!

[kafercup]

updates??

[petevw]

Wow nice ride. I had missed it

[tom'72]

updates??

Haven't had much time to work on it lately but had a few problems.

First the engine wouldn't fire, turned out the crank sensro wasn't sending a signal to the ECU. Ordered a new crank sensor but it still wouldn't fire.

Will have to check each wire, ground and connector for any faults.

[kafercup]

Haven't had much time to work on it lately but had a few problems.

First the engine wouldn't fire, turned out the crank sensro wasn't sending a signal to the ECU. Ordered a new crank sensor but it still wouldn't fire.

Will have to check each wire, ground and connector for any faults.

Can you give me some details on how you went about installing the side scoops?

[tom'72]

Can you give me some details on how you went about installing the side scoops?

I first made a cardboard template of the scoops shape and then made that about 1cm smaller all around.

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820194_large.jpg

Then I positioned that template on the body and cut it out ( this hole is now 1 cm smaller all around then the outer dimensions of the scoop.
Then I used a special type of pliers (have no idea how it's called in English) to make the body pannel where the scoop will be glued over fall just a bit deeper (think its 2mm) then the rest of the pannel so the scoop sits flush in the body.

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820195_large.jpg

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820196_large.jpg

You can see how the edge where the scoop will be lies a bit deeper here.
http://memimage.cardomain.com/ride_images/1/3378/2641/8443820206_large.jpg

[tom'72]

The scoops are glued in place and I used a black sealent (looks and feels like silicone) to finish the outer edge ( am going to do that again as my first attempt wasn't as good as it should be).

http://memimage.cardomain.com/ride_images/1/3378/2641/8443820218_large.jpg

[SilverBullet]

The rear wheels out alittle would be nice

[tom'72]

http://www.youtube.com/watch?v=0XH4vFT4AX8

Hopefullly will be able to finish up suspension, gears, clutch and gas cable + lots of other bits that need tidying op over the next week or so and then take it for a test drive

[excello]

:eekno: WOW :eekno:
That made the hair in my nek stand up. Nice!!!!