Germanlook/Rallylook Beetle

[72marinablue]

Well instead of making multiple threads about new additions to my car I have decided to make a ongoing build thread for it. Here I can consolidate my progress. My goal has always been to bring my Beetle up to more modern standards, and making it perform better. I have never had the goal of making my car track worthy nor "rally" worthy yet I love the look. This is my first car and has been my daily driver for the last 5 years. I have put countless hours of time into this car and it has been both my therapy and my obsession.

The newest addition (Christmas present to myself) would be the Kamei spoiler. ITS LOW!

http://i150.photobucket.com/albums/s99/72marinablue/IMG_0790edit.jpg~original
http://i150.photobucket.com/albums/s99/72marinablue/IMG_0799edit.jpg~original
http://i150.photobucket.com/albums/s99/72marinablue/IMG_0786edit.jpg~original

And the Nardi wheel.

http://i150.photobucket.com/albums/s99/72marinablue/IMG_0745.jpg~original

[chug_A_bug]

that Kamei Looks SWEET... nice Score from Ebay ;)

Chris.

[owdlvr]

Looking good! Now lets see some photos of how you mounted it, you know...for archives sake.

-Dave

[Humble]

I love that look :thumbup:

Make sure you secure the spoiler to the fenders though or the mouting tabs will break.

[72marinablue]

Wow didn't even think of that! Good advice!

[1303GT]

Nice, I like the look.

I'm building a 74 1303 in the same spirit.

[Steve C]

Hi

Looking very GL, have you tried it on the highway yet, the Kameis really make a difference.

Steve

[NO_H2O]

Very nice. Watch those speed bumps and curbs. The Kamei is made of ABS plastic so it is forgiving to a point.

[owdlvr]

Drat. This is making me think my '69 needs one.

;-)

-Dave

[72marinablue]

I am actually thinking about supporting the front of the spoiler from the front similar to like this
http://www.ssdd-motorsport.com/images/products/247-1.pjpeg

You can buy the supports. I would attach it to the spoiler itself and the bottom of the bumper.

[kuleinc]

I'll try topost picks of my Kamei spoiler supports... They're a little more stealthy than the BMW ones in that pic... and don't require drilling holes in your fenders...

[72marinablue]

That would be much appreciated!

[kuleinc]

It involves bolting a plate to the bumper bracket bolt and one to the hole in the spoiler and getting a piece of rod and welding it to each plate. I can't find any pics right now, but if you use the right bumper bolt and position the plates in the right way the rod connecting them should clear the fender no problem!

[70Turbobug]

Great pics! I like the BBS wheels too - very classy!

[72marinablue]

Finally put a 20mm adjustable whiteline swaybar on the front of the car. The handleing is really coming together. WAY more stable in the curves. Just waiting on my rear swaybar and then ill be golden!

[72marinablue]

Well I havent posted here in awhile but I have a big project.

Type 4 POWER!

Currently the powertrain is a stock 1600dp with pointless ignition and an svda. Im really looking forward to having some extra power driving the rear wheels, and perhaps a higher geared trasmission for better highway cruising since I have a smaller diameter tire on my car.

http://i150.photobucket.com/albums/s99/72marinablue/9146d902.jpg

http://i150.photobucket.com/albums/s99/72marinablue/GraffitiTall.jpg

I have been searching for a 1.8 liter 914 engine on craigslist for a couple years and last week I finally found what I wanted. A pretty clean longblock and duel solex carburetors. the engine came with everything, all cooling tin was intact.

http://i150.photobucket.com/albums/s99/72marinablue/5101b74d.jpg

After the engine was torn down to the longblock

http://i150.photobucket.com/albums/s99/72marinablue/9d593194.jpg~original
At this point the engine was completely dissasembled.

http://i150.photobucket.com/albums/s99/72marinablue/035ce84b.jpg

I did find some funky stuff in the sump plate, seems like it was never cleaned out. What looks to be a rock of some sort, some wood or bark, and some type of plant seed or bug or something. Donno

http://i150.photobucket.com/albums/s99/72marinablue/9c49a19a.jpg

I only had one concern about the engine while I was tearing it down. The engine didnt come with the flywheel (ok since I wont be able to use it anyway) and when I got it home I realized there was about a 1/4 " of play in the crankshaft, I could literally grab it and move in back and forth in the case. Im sure that this is not good but i didnt notice anything considerably wrong when I opened up the case. Bearing wear and thats about it. Have any ideas what it could have been?

Here are some internal picks including the heads (large valves!), main bearings that I can see, camshaft lobe wear.

http://i150.photobucket.com/albums/s99/72marinablue/7f797dae.jpg
http://i150.photobucket.com/albums/s99/72marinablue/931c52fd.jpg
http://i150.photobucket.com/albums/s99/72marinablue/69289e74.jpg
http://i150.photobucket.com/albums/s99/72marinablue/82e408be.jpg

Looks like something got loose in this cylinder at some point in the engines life. I believe it was from a previous rebuild as I didnt see any marring or damage in the corresponding piston.

http://i150.photobucket.com/albums/s99/72marinablue/a1858fbd.jpg

Definetly has some funky camshaft lobe wear as well as what looks to be some indentation in the lifters.

http://i150.photobucket.com/albums/s99/72marinablue/18717de7.jpg
http://i150.photobucket.com/albums/s99/72marinablue/10929aff.jpg
http://i150.photobucket.com/albums/s99/72marinablue/f46d0ee5.jpg
http://i150.photobucket.com/albums/s99/72marinablue/a3a3f41d.jpg

Different wear
http://i150.photobucket.com/albums/s99/72marinablue/7619920b.jpg

And finally some main bearing wear, they look pretty crappy if you ask me.

http://i150.photobucket.com/albums/s99/72marinablue/d0e93347.jpg
http://i150.photobucket.com/albums/s99/72marinablue/ae5be9c8.jpg
http://i150.photobucket.com/albums/s99/72marinablue/2fbc50e9.jpg
http://i150.photobucket.com/albums/s99/72marinablue/67121d89.jpg

let me know if you guys can give me any hints as to what kind of life this engine has lived, I plan to build a 2056 with rat cooling so almost all parts will be replaced including crank, rods, p/c, valvetrain. I am planning on getting the heads rebuilt with 46/34 valves, I will be sticking them in the oven soon to check for cracks.

[Steve C]

Hi

Looks like a good start.

The marking in the combustion chamber is often caused by an accelerator pump jet falling out of the carby and getting massed up, this is a very common occurrence.

When no flywheel is fitted it is normal for the crankshaft to move like you described.

Steve

[72marinablue]

Woke up to a text this morning from my buddy saying I had a picture In this months Eurotuner Magazine! Excited to say the least that out of the over 1000 cars at the Leavenworth Cruise they decided to put a picture of my car in the article!

http://i150.photobucket.com/albums/s99/72marinablue/photo-3.jpg~original

Still working on my type 4 conversion. I have decided to go with either a stock 2 liter displacement or go up to 2056 with 96mm p/c's. I have already sourced a 2 liter crank and rods and still need to purchase valvetrain parts and p/c's. I am on a pretty tight budget so I am not going to crazy so I have elected to go with the Joe Cali conversion shroud and I am going to try and keep it as stock looking as possible. Flat black and silver.

[owdlvr]

Leavenworth!?!

For some reason I always thought you were in Europe. I missed the cruise this year by simply mixing up the dates in my head. As stated, don't worry about the crank movement. I would have the crank checked/measured due to those bearings though. Doesn't look too bad, but better to be safe. If you get stuck for internal parts I may have what you need, I'm just North of Vancouver Bc.

-Dave

[72marinablue]

Wow, I had no idea you are so close. I follow your build thread religiously and am a huge fan of your cars. I am in Tacoma, Wa. I actually picked up a set of 2 liter rods and crank that appear to be in good condition, and the one originally pictured is the 1.7/1.8 crank. Im going to take a bunch of parts up to Northwest Connecting Rod to have them checked out. Hope to see you and one of your cars next year at the cruise:thumbup:

[72marinablue]

Also forgot to mention I made a welcome addition to my interior. Recaro seats from a MkII gti/gli. The perfect mix of comfort and support. I welded a couple pieces of flatbar to a stock set of seat bases and the seats bolt on to those. This puts the seats at a perfect level.

http://i150.photobucket.com/albums/s99/72marinablue/35cb1698.jpg~original

[Humble]

Nice shot in the magazine :)

Those seats are one of my fav's, good find!

[NO_H2O]

I have a nice pair of those seats down in the shop. I plan to put them in my son's bug one of these days.

[72marinablue]

Its been awhile. I like this forum and still check it occasionally. The type 4 motor didn't work out. I was too young and didn't have enough time, money or experience to make it happen. Now is a different story.

I am currently in the process of installing an ej22 motor from a 1993 Legacy into my bug, and just wanted to share some of the things that I have done to make it a clean install. Currently I have the wiring harness done, but not shortened and fitted to my car. I am in the process of fabricating the exhaust, and making changes to the engine that will be handy later. I will let the pictures speak for themselves.

Things I have knocked off the list

Wiring harness
Sump stock fuel tank
Run 3/8" fuel lines through the tunnel and into the engine compartment
Shortened oil sump and pickup tube
Reversed coolant manifold (will add pictures later)
Many more things to come

I was rear ended a couple years ago and it really messed the car up. I have most of the body back to where it needs to be, but getting it moving under its own power is my major motive at the moment.

http://images.thesamba.com/vw/gallery/pix/1455824.jpg
http://images.thesamba.com/vw/gallery/pix/1455823.jpg
http://images.thesamba.com/vw/gallery/pix/1455822.jpg
http://images.thesamba.com/vw/gallery/pix/1455821.jpg
http://images.thesamba.com/vw/gallery/pix/1455820.jpg
http://images.thesamba.com/vw/gallery/pix/1455819.jpg
http://images.thesamba.com/vw/gallery/pix/1455818.jpg
http://images.thesamba.com/vw/gallery/pix/1455817.jpg
http://images.thesamba.com/vw/gallery/pix/1455816.jpg
http://images.thesamba.com/vw/gallery/pix/1455815.jpg
http://images.thesamba.com/vw/gallery/pix/1455814.jpg
http://images.thesamba.com/vw/gallery/pix/1455813.jpg
http://images.thesamba.com/vw/gallery/pix/1455811.jpg
http://images.thesamba.com/vw/gallery/pix/1455810.jpg

[Jadewombat]

Sorry to hear about the accident. An insurance company will never know the hundreds of hours we put into these cars nor will some idiot who hits you.

Maybe it's my computer, but I can't see the photos on your newest post.

[72marinablue]

Sorry to hear about the accident. An insurance company will never know the hundreds of hours we put into these cars nor will some idiot who hits you.

Maybe it's my computer, but I can't see the photos on your newest post.

Hmmm, not sure why you cant see the pictures. I have looked on several different computers and they work.

Dealing with the insurance company when haggling for the value of my car was the biggest pain in the ass. I hate insurance companies.

[72marinablue]

About done with the fabrication work for my header. Waiting on a vband flange that will connect the header to the canister style muffler i plan on making. I want the exhaust to exit out the stock location. You can see the amount of clearance i will get with this setup now. Before I make the muffler portion I plan on doing a test fit of what i have so far.

http://images.thesamba.com/vw/gallery/pix/1459831.jpg
http://images.thesamba.com/vw/gallery/pix/1459830.jpg
http://images.thesamba.com/vw/gallery/pix/1459829.jpg

[cookvw]

that header looks awesome!

[72marinablue]

that header looks awesome!

Thank you! It has been fun making it.

Here is a picture of the reverse coolant manifold that I made. I have a lathe at work so I made up the segment and welded in as an extension. It lines up straight with the car and fits under the intake manifold nicely.

http://images.thesamba.com/vw/gallery/pix/1460235.jpg
http://images.thesamba.com/vw/gallery/pix/1460234.jpg

[Steve C]

nice work, is your header high enough? I scrape my cross pipe flanges all the time

http://i1184.photobucket.com/albums/z328/1303Steve/EJ%20crank%20pulley%20tool_zpsx3df5hum.jpg~origina l (http://s1184.photobucket.com/user/1303Steve/media/EJ%20crank%20pulley%20tool_zpsx3df5hum.jpg.html)

[72marinablue]

nice work, is your header high enough? I scrape my cross pipe flanges all the time



I hope so! At the moment its about 1/8" higher than my chopped oil pan, which is only about a 1/4" lower than my oil filter. So I am hoping it will do the job! My beetle is pretty low, but if i need to raise it for more ground clearance or go with a different wheel/tire package I am not opposed to it.

[Steve C]

Its hard to tell from photos, I lifted my trans 25mm and moved it forward 100mm, moving it forward really helps on speedbumps etc as the wheels lift it over the bump

[72marinablue]

So I built this extension onto the thermostat housing, Its pretty stout but I am still unsure about it. Trying to make pulling the engine out very easy, and also not a huge fan of running a rubber tube by the exhaust header. Ill probably just run it until it cracks or gives me issues.

http://images.thesamba.com/vw/gallery/pix/1465032.jpg

But I am happy because I did the first fit up of the engine in the car! The exhaust looks like it is going to work perfectly, I just have to figure out how I want to make the custom muffler. The tips will definitely be coming out of the stock location, and I am planning on making some sort of canister muffler. Its all a big experiment but thats what makes it fun!

http://images.thesamba.com/vw/gallery/pix/1465031.jpg

http://images.thesamba.com/vw/gallery/pix/1465030.jpg

http://images.thesamba.com/vw/gallery/pix/1465028.jpg

My reversed coolant manifold is pointing just a tad high, so I will be adjusting that for better fit. On the plus side ground clearance looks great! Lower than before, but not crazy low.

[72marinablue]

Getting my coolant system figured out. I made some nifty brackets to hold the tubing to the floor, they will be isolated with rubber for final fitment. The front of the tubes are done, they both snake through the passenger side beam to the radiator which will sit at a slight angle. The radiator is a nice griffin unit that fits perfectly in the spare tire well, I also have a nice spal fan that I will be using to pull air in when its needed. I have a unique idea that I am going to run with for how I am going to get air to the front of the radiator, and it involves something rather special thats on its way from France right now, so stay tuned!

http://images.thesamba.com/vw/gallery/pix/1477870.jpg
http://images.thesamba.com/vw/gallery/pix/1477869.jpg
http://images.thesamba.com/vw/gallery/pix/1477868.jpg
http://images.thesamba.com/vw/gallery/pix/1477867.jpg

[72marinablue]

I know now without a shadow of a doubt that I am a hoarder........ and that there is a definite difference between a Kamei spoiler for a standard beetle and a super. Here is the photographic evidence that just showed up in the mail! Woohoo! btw I have extensive experience working with fiberglass and composites, and plan on making some molds. Ideally I would like to vacuum form them from abs but that might prove difficult with my resources.

http://images.thesamba.com/vw/gallery/pix/1481245.jpg

http://images.thesamba.com/vw/gallery/pix/1481244.jpg

http://images.thesamba.com/vw/gallery/pix/1481243.jpg

http://images.thesamba.com/vw/gallery/pix/1481242.jpg

http://images.thesamba.com/vw/gallery/pix/1481241.jpg

You can see from the pictures that the super beetle spoiler that I have had for years is substantially bigger, and has different locations cut into the top for bumper mount clearance.

[vw1303]

Keep up the good work! I love the pie cuts:)

[effvee]

Well your project looks good. However, seeing the room left in your compartment, I don't see a six cylinder being able to fit. Ah, man.

[francisco_neto]

News?

[effvee]

News?

Good morning, please clarify your response?

[francisco_neto]

Good morning, please clarify your response?
Hello, effvee.

It's been a while since the last post from 72marineblue. SO.. that's why I posted the "news?". :)

I'm curious about the newest upgrades. :D

[72marinablue]

Still working! Ill gets some pictures together and post an update.

[72marinablue]

Time for an update. Slow progress but forward progress.

I made a custom muffler with internal baffling-

https://www.thesamba.com/vw/gallery/pix/1718861.jpg

Did some dress up on the engine-

https://www.thesamba.com/vw/gallery/pix/1718858.jpg
https://www.thesamba.com/vw/gallery/pix/1718860.jpg
https://www.thesamba.com/vw/gallery/pix/1718856.jpg

Custom oil fill tube-

https://www.thesamba.com/vw/gallery/pix/1718859.jpg

I also made a rear overflow tank that is plumbed into the heater circuit. Its attached with riv-nuts and allen heads now, the screws were for mockup. On the backside of the tank is a hole through the parcel tray that goes to a electric heater core unit that jegs/summit sell. http://www.jegs.com/i/JEGS-Performance-Products/555/70601/10002/-1?CAWELAID=1710590108&CAGPSPN=pla&CAAGID=39714413703&CATCI=aud-300525381019:pla-192574173191&CATARGETID=230006180039221023&cadevice=c&gclid=CjwKCAiAu4nRBRBKEiwANms5W3GVtMi5tFg9-6obOFBEGcfHnIVqrDmW_jVMIQdhJBk0uOeWlHWv7RoCoWEQAvD _BwE It has two 3" outlets that will run back throught the parcel tray and into the factory heater channels. I will have multiple air speeds for the electric fan, and use of the factory levers for different air flow. I think it will work perfect.

https://www.thesamba.com/vw/gallery/pix/1718857.jpg

This was fun to make. Finished up my airbox today. I also made the velocity stack inside, probably won't make a difference, but I have never made them before and wanted to give it a try. I am going to remove the foam in the rear pillar between the vent behind the rear window and the engine bay in an attempt for a "cold air" intake. I couldn't bring myself to use a cone filter floppin around in the engine bay, but I am a little crazy with stuff like this.

https://www.thesamba.com/vw/gallery/pix/1721101.jpg

https://www.thesamba.com/vw/gallery/pix/1721102.jpg

https://www.thesamba.com/vw/gallery/pix/1721100.jpg

https://www.thesamba.com/vw/gallery/pix/1721099.jpg

https://www.thesamba.com/vw/gallery/pix/1721095.jpg

https://www.thesamba.com/vw/gallery/pix/1721094.jpg

https://www.thesamba.com/vw/gallery/pix/1721093.jpg

https://www.thesamba.com/vw/gallery/pix/1721092.jpg

https://www.thesamba.com/vw/gallery/pix/1721091.jpg

[chug_A_bug]

WOW the Workman Ship...

[owdlvr]

Brilliant! Now that I have a Subaru donor for the next project, I'm going to have to re-read...and expect you to post more often :D ;)

-Dave

[72marinablue]

Brilliant! Now that I have a Subaru donor for the next project, I'm going to have to re-read...and expect you to post more often :D ;)

-Dave

Haha I’ll do my best. My time is mostly taken up by working on my bosses projects but I’d really love to get my car back on the road by next summer. Love your build Dave. If your ever down in the Seattle/Tacoma area I’d love to see it in person.

Forrest,

[rioprelude]

Nice work! I would love to have access to the machinery in the pics!

I see that you moved some of the pics from photobucket to thesamba. I've been thinking about starting a new gallery here on germanlook, that supports full size images, since cloud storage is so cheap.

[owdlvr]

Haha I’ll do my best. My time is mostly taken up by working on my bosses projects but I’d really love to get my car back on the road by next summer. Love your build Dave. If your ever down in the Seattle/Tacoma area I’d love to see it in person.

Forrest,

I used to be in Seattle a TONNE, visiting Blake at NorthWest Auto Salon. Warwick used to have an office at Dirtfish, and I was out there six or seven times a years...but since moving to the island I make the trip only a paltry two or three times a year.

I will be in Seattle early September for Global Rallycross, and then passing through to Oregon middle of September for my CCA Hagerty Fall Classic event. Could definitely bring the Rally Bug down to one of those events.

Get your GL project finished in time for the Fall Classic!

-Dave

[72marinablue]

Nice work! I would love to have access to the machinery in the pics!

I see that you moved some of the pics from photobucket to thesamba. I've been thinking about starting a new gallery here on germanlook, that supports full size images, since cloud storage is so cheap.

Yeah I really hated using photobucket. The sambas gallery interface is super easy. You can upload a bunch of pictures all at the same time, and I can do it directly from my phone which is a major plus as thats what I use to take all the pictures.

I used to be in Seattle a TONNE, visiting Blake at NorthWest Auto Salon. Warwick used to have an office at Dirtfish, and I was out there six or seven times a years...but since moving to the island I make the trip only a paltry two or three times a year.

I will be in Seattle early September for Global Rallycross, and then passing through to Oregon middle of September for my CCA Hagerty Fall Classic event. Could definitely bring the Rally Bug down to one of those events.

Get your GL project finished in time for the Fall Classic!

-Dave

Ill have to make an effort to see it, and check out your event. Seems as if you are a big car guy like me. I am Richard Griot's shop foreman at Griots Garage if you have ever been to our headquarters in Tacoma. I manage his collection and maintain/restore/fabricate along with about a dozen other hats. If your ever in town and want to see some very rare and unique stuff stop by and ask for me and Ill show you around.

Forrest

[owdlvr]

Hahahaha, no way. We probably know many mutual friends/contacts!

I will definitely add a shop tour to my next trip's agenda.

-Dave

[72marinablue]

The last bit of the intake puzzle coming together. Had to go with the pie cuts for........ consistency sake with the rest of the build :Ds

I made a fitting that slips over the MAF with a very nice interference fit, and welded the tubing to the inside to start the piping. Everything is tacked together but I ran out of argon over the holiday weekend so I'll have to finish next week :(. The tubing will get a silicone coupler to mate up with the throttle body. You can see the welding wire I bent at the same curvature as the decklid so I could guarantee fitment.

https://www.thesamba.com/vw/gallery/pix/1728310.jpg

https://www.thesamba.com/vw/gallery/pix/1728307.jpg

https://www.thesamba.com/vw/gallery/pix/1728309.jpg

https://www.thesamba.com/vw/gallery/pix/1728308.jpg

Happy New Year!

[ricola]

Looks nice but I think you'll need to allow for more movement than a silicone joiner so short will allow and you will end up damaging the MAF..

[72marinablue]

Looks nice but I think you'll need to allow for more movement than a silicone joiner so short will allow and you will end up damaging the MAF..

You could be right, Ive been thinking about that.

[Steve C]

You could be right, Ive been thinking about that.

You can buy hump hose in silicone that would give you some movement

[beetle1303]

How about putting another silicone bit where the MAF is, or in the middle where you have a straight bit?

Just an idea...

Feels great posting after all this time..

Cheers
Chris

[72marinablue]

Ive switched gears a bit and am working on getting my new front clip figured out before I weld it to the car. Working on some support while maintaining airflow and I also made a fan shroud for my Spal puller fan.

https://www.thesamba.com/vw/gallery/pix/1738129.jpg
https://www.thesamba.com/vw/gallery/pix/1738130.jpg
https://www.thesamba.com/vw/gallery/pix/1738128.jpg
https://www.thesamba.com/vw/gallery/pix/1738127.jpg
https://www.thesamba.com/vw/gallery/pix/1738126.jpg
https://www.thesamba.com/vw/gallery/pix/1738131.jpg

[Wally]

Nice fabrication!

[Jadewombat]

Great stuff. You used a bead roller or hammerformed the raised edges on those pieces?

[72marinablue]

Nice fabrication!

Thanks man! Your car has always been a huge inspiration for me.

Great stuff. You used a bead roller or hammerformed the raised edges on those pieces?

I made a simple hammerform for the front clip piece, I used a bead roller for the radiator raised section and pre-stretched the area with an english wheel.

[Jadewombat]

Nice.

[72marinablue]

Well this place is pretty empty these days but I figured I should post some pictures anyway. After many years I am almost done. So many modifications too much to list. If anyone here is on instagram feel free to send me a message on there @forrest__davis

https://www.thesamba.com/vw/gallery/pix/2298501.jpg
https://www.thesamba.com/vw/gallery/pix/2298498.jpg
https://www.thesamba.com/vw/gallery/pix/2298502.jpg
https://www.thesamba.com/vw/gallery/pix/2298503.jpg
https://www.thesamba.com/vw/gallery/pix/2298504.jpg
https://www.thesamba.com/vw/gallery/pix/2298505.jpg
https://www.thesamba.com/vw/gallery/pix/2298506.jpg
https://www.thesamba.com/vw/gallery/pix/2298507.jpg

[Steve C]

Nice work, have you driven it yet, must be a blast

[412STi]

Wouh!!

Really nice car.
Can you possibly post an audio recording?
Would like to hear the sound of the exhaust.
Possibly also driving?

Thank you.

[72marinablue]

I’m still doing some initial shakedown but it is clearly going to be a completely different car than before. I’m really happy with the power level as 150hp and all the Subaru torque really pulls the car along. Here is a short video-

https://www.instagram.com/p/CeoOBkYt2qz/?hl=en

[412STi]

Thank you.

Sounds really good.
Have fun with the beautiful babe.
Hopefully with little to no problems.

[Mr_Zed_ZX20]

I'm getting ready to replace the long block in my turbo Forester and I've considered doing a similar swap in the future. I didn't realize you're here in Washington, I'm in the Yelm area.

[72marinablue]

Well so far I have about 300 miles on the Beetle. It has been pretty hot in the PNW and I was experiencing higher coolant temps then I was really comfortable with. The car would climb up to 210 when in traffic and the fan wasn't powerful enough to get it back down near 195 which is where the subaru ecu shuts the electric fan back off. I decided to nearly double my CFM of the radiator fan and revised a new fan shroud with rubber flaps that should open at highway speeds but close when the fan is running. I also redesigned my 3d printed intakes in front of the Kamei spoiler to get more direct force fed air while driving at higher speeds. This all seems to have done the trick and she stays plenty cool now even in hot weather. I have mostly been working on finishing the interior at this point, still need to do carpet, seat upholstery etc. The latest fab project is a rear seat "delete." I like the way the rear seat looks but I dont plan on ever having any passengers. I have been building this box to go in the same place, allow a bit more clearance than the actual seat to the backs of the recaro's and also function as a storage space for tools, access to battery etc.
https://www.thesamba.com/vw/gallery/pix/2320952.jpg
https://www.thesamba.com/vw/gallery/pix/2320951.jpg
https://www.thesamba.com/vw/gallery/pix/2320949.jpg
https://www.thesamba.com/vw/gallery/pix/2320946.jpg
https://www.thesamba.com/vw/gallery/pix/2320945.jpg
https://www.thesamba.com/vw/gallery/pix/2320943.jpg
https://www.thesamba.com/vw/gallery/pix/2320956.jpg
"

[El_Bandito]

Absolutely love how this car has turned out. Stunning.

[72marinablue]

Absolutely love how this car has turned out. Stunning.

Thank you!

I finished my rear seat delete/compartment and have been using it for a couple months. It is very handy and allows me to story my toolbox and other items so they aren't floating around the car. I also have built my own steering wheel. I started with a 914 steering wheel that looked like it came from the bottom of a lake. That didn't matter for me as i just needed the metal frame. My inspiration was the early steering wheels in late 60's 911's with the batwing horn button. I like these steering wheels a lot but I wanted a smaller diameter hence the 914 starting point. I laminated many layers of veneer mahogany to make 2 blanks for the front and backside. Lots of routing of different radii of the outside dimensions as well as a groove for the metal ring of the steering wheel. Some stain, powdercoat, and satin finish and I have something that I am extremely happy with. The batwing style horn button was a lot of work, with many individual pieces welded together and filed smooth.

I believe the most important parts of any car are the points that a driver comes directly in contact with. The seats, the steering wheel, the shifter, and the pedals being the highest priority. This was a fun project to make something a bit more special than what was available off the shelf.

https://www.thesamba.com/vw/gallery/pix/2365098.jpg

https://www.thesamba.com/vw/gallery/pix/2365096.jpg

https://www.thesamba.com/vw/gallery/pix/2365095.jpg

https://www.thesamba.com/vw/gallery/pix/2365097.jpg

https://www.thesamba.com/vw/gallery/pix/2365094.jpg

https://www.thesamba.com/vw/gallery/pix/2365093.jpg

https://www.thesamba.com/vw/gallery/pix/2365092.jpg

https://www.thesamba.com/vw/gallery/pix/2365090.jpg

https://www.thesamba.com/vw/gallery/pix/2365089.jpg

https://www.thesamba.com/vw/gallery/pix/2365088.png

[owdlvr]

That steering wheel is fantastic. Well, the whole car is.

Geesh. We're 270 miles apart, we really should get together this year.

[wouter1303]

woah, killer job on that steering wheel!

[72marinablue]

That steering wheel is fantastic. Well, the whole car is.

Geesh. We're 270 miles apart, we really should get together this year.

Lets do it Dave!

[LLVWGL]

Well this place is pretty empty these days but I figured I should post some pictures anyway. After many years I am almost done. So many modifications too much to list. If anyone here is on instagram feel free to send me a message on there @forrest__davis

https://www.thesamba.com/vw/gallery/pix/2298501.jpg
https://www.thesamba.com/vw/gallery/pix/2298498.jpg
https://www.thesamba.com/vw/gallery/pix/2298502.jpg
https://www.thesamba.com/vw/gallery/pix/2298503.jpg
https://www.thesamba.com/vw/gallery/pix/2298504.jpg
https://www.thesamba.com/vw/gallery/pix/2298505.jpg
https://www.thesamba.com/vw/gallery/pix/2298506.jpg
https://www.thesamba.com/vw/gallery/pix/2298507.jpg


Nice work! Always interesting to see how to incorporate the radiator in a discreet way!

[72marinablue]

I think Dave keeping his threads alive has inspired me-

Earlier this summer I wrapped up the interior of the car. I purchased my own bulk square weave carpet and made my own carpet kit. I used vinyl as my binding and broke out my 1950 singer sewing machine.

https://www.thesamba.com/vw/gallery/pix/2442279.jpg

I was also able to work in my buddies upholstery shop down the street and got my first go at some real upholstery work sewing a cover for my back seat that matches my door panels.

https://www.thesamba.com/vw/gallery/pix/2442275.jpg
https://www.thesamba.com/vw/gallery/pix/2442274.jpg

I made a speaker tray for the rear to cover my heater and associated engine wiring/ecu. I also inset 2 cool vintage ads speakers but currently don't have any pictures.

https://www.thesamba.com/vw/gallery/pix/2442273.jpg

I was pretty annoyed with my walbro fuel pump situation. It was located below the tank on the shelf in-front of the passenger footwell. It had issues during the summer when it was hot and the fuel level was low, causing the pump to get too hot as its cooled using the fuel it flows. It was also annoying and loud. The best style pump is really an in-tank setup for fuel injection cars as the pump sits in the fuel and this helps it maintain temperature and keeps it quiet. I also think I was having aeration issues as the fuel was returning into the tank at a less then ideal location. Ive learned since that the return line should dump fuel under the fuel level, this helps keep aeration to a minimum.

I decided to build my own in-tank setup as I didn't like the aesthetic of the aftermarket options. I already had a baffle in the tank so I used this same location but made my own holder utilizing a factory subaru denso pump. I struggled to find a wiring passthrough that would keep the fuel sealed into the tank, and ultimately purchased a fuel lab hermetic unit that has worked great but was a bit expensive.

https://www.thesamba.com/vw/gallery/pix/2442277.jpg
https://www.thesamba.com/vw/gallery/pix/2442278.jpg
https://www.thesamba.com/vw/gallery/pix/2442276.jpg

I did a few aesthetic upgrades as well since I have been content with my cooling package. I remade my radiator surround, it is painted body color now. I also painted a few 3d printed items including my front radiator intakes as previously they were raw plastic.

https://www.thesamba.com/vw/gallery/pix/2442270.jpg
https://www.thesamba.com/vw/gallery/pix/2442271.jpg

Other than that I have really been enjoying driving the car. I have taken it to a few events, and recently took it up a local mountain pass that is a great twisty road. The Subaru engine really makes the car a joy to drive and pulling up the road in 4th gear on a steep slope feels so foreign after driving the car with 50hp for so long.

https://www.thesamba.com/vw/gallery/pix/2442269.jpg
https://www.thesamba.com/vw/gallery/pix/2442268.jpg
https://www.thesamba.com/vw/gallery/pix/2442224.jpg
https://www.thesamba.com/vw/gallery/pix/2442223.jpg
https://www.thesamba.com/vw/gallery/pix/2442225.jpg

I am still hoping to add a subaru transaxle to the mix as I would love to drop the cruising rpm's. I have a donor transaxle ready to go but am waiting for the right financial opportunity to purchase a r&p setup from subarugears.

Hope everyone has great workshop plans for the winter.

Forrest,

[owdlvr]

The build quality on this is phenomenal. Ugh. I really need to up my game!

(actually spending some time on my to-be-subaru-powered 1303 wouldn't be a terrible idea either...)

-Dave

[Wally]

The build quality on this is phenomenal. Ugh. I really need to up my game!



I can only second the above. You really are extremely crafty and seem to be able to do everything, even interior/upholstery!
Big kudos!!

[72marinablue]

The build quality on this is phenomenal. Ugh. I really need to up my game!

(actually spending some time on my to-be-subaru-powered 1303 wouldn't be a terrible idea either...)

-Dave

I can only second the above. You really are extremely crafty and seem to be able to do everything, even interior/upholstery!
Big kudos!!

Big thanks to both of you. I have looked up to your car for a long time Wally, and also Dave's many projects. I was looking how long I have been on the forum yesterday and its been since 2007 which is almost as long as Ive owned the car :eek:. I always dreamed of being able to build the car how I wanted with inspiration from other people on this forum and its been a blast learning and bringing it to fruition.

Forrest,

[owdlvr]

Can I get a link to your photobucket or where you've been hosting photos? They aren't showing up for me in the thread :D

[72marinablue]

Nothing much to share besides some pictures. I am working on a rear spoiler design, trying to tie in the aggressive look of the front kamei spoiler into the rear. At one point I built a duckbill for the rear decklid but aesthetically i think its a bit much, so I have designed something for the rear window area shaped out of aluminum. I will most likely paint this satin black like some of the other components/front spoiler.

https://www.thesamba.com/vw/gallery/pix/2453701.jpg

https://www.thesamba.com/vw/gallery/pix/2453704.jpg

About 17 years ago I took this picture in Gig Harbor Washington where I grew up. I had it printed and its lived in my house/apartments ever since. I wanted to redo the photo in current day-

https://www.thesamba.com/vw/gallery/pix/2453698.jpg
https://www.thesamba.com/vw/gallery/pix/2453703.jpg
https://www.thesamba.com/vw/gallery/pix/2453702.jpg

[72marinablue]

The spoiler previously mentioned-

https://www.thesamba.com/vw/gallery/pix/2453699.jpg

[wouter1303]

nice craftmanship! and different than other designs of roof spoilers. I like it.
Are you going to color code it or leave it as is?