View Full Version : '69 / '76 Germanlook Project

January 17th 2010, 16:27
i started this project october 2008 - starting with a 1976 body and 1969 chassis. I started off with a 1976 beetle i had since i was 15 - and acquired a 1969 chassis to IRS.

a couple of pics before



First up was new heavy duty floorpans and IRS conversion with 944 Turbo a arms





with this being shoe horned in next!


The chassis has also received a couple of small repairs to the framehead, a hydraulic clutch set up a a bug@5 speed shifter





the clutch MC was fitted through the inspection hole (had to be slightly enlarged) and a hole made behind the throttle lever arm cover for access



i think this is a much better way of installing it rather than cutting a large hole in the top of the tunnel as suggested :)

January 17th 2010, 16:39
The body has also received extensive work with 2 new heater channels, new front bulkead, 2 new a posts, 1 new front quarter, new front apron / wheel well and panel below the petrol tank. 2 new rear quarters, 2 rear cross members, new rear valance, new front scuttle, 2 boot floor repairs and a couple of small gutter repairs. All panels were NOS with the exception of the a posts (hookys) and the wheel trough panel.












The car was then completely stripped and sandblasted - the coated with kephos







and the man doing the blasting - alex from abs blasting


hopefully my gearbox mount will be finished this week so i may get that fitted- and im also starting to prep the bolt on panels this week. :)

January 17th 2010, 21:36
Those are some nice MIG welds on the IRS pivot brackets. Well, from the progress so far looks like this bug will be on the road soon then. I'm going to start some rust repairs on my bugs body pretty soon, doing alot of what you have done already. This is good inspiration for me, and others I'm sure! Keep it up!:D

January 17th 2010, 23:07

January 22nd 2010, 18:53
Thans for the kind comments :)

. ive just received my aluminium gearbox mount adapters from a friend so the rear cradle is now bolted to the gearboxx - when we get some room in the workshop il get the chassis back down and finish fitting the gearbox.

at the moment im just prepping the bolt on panels for paint. not very interesting so i wont bother posting pics of that.



January 22nd 2010, 18:55
Wrernchnride from the looks of your build so far - the body will not be a problem for you - do you do it as a job also? im awaiting pics of your clutch slave cylinder install as ive still gota do mine ;) Think im going to mount mine similar to Wally.

January 22nd 2010, 22:01
Wrernchnride from the looks of your build so far - the body will not be a problem for you - do you do it as a job also? im awaiting pics of your clutch slave cylinder install as ive still gota do mine ;) Think im going to mount mine similar to Wally.

Thanks. The work is no problem...getting the time to work on it is though ;) . This is not what I do for a living (wish I could). By trade I'm a industrial mechanic so must perform many types of repair and rebuilding. My slave cylinder install is on hold due to work hours, building my header, and a friends motorcycle I'm rebuilding the engine on.

January 23rd 2010, 01:11
Good looking project so far. Keep the pix coming.

January 24th 2010, 08:53
ive got loads of pics of the body resto - but didnt want to bore you guys with all of those.

yesterday my gearbox blocks to mount on the beetle cradle turned up and they work nicely :) i just need to get some countersink bolts but this is it mocked up. im going to bolt it in and then mock up the front mount which i have all the bits for it just need welding together!

i also ordered some 4cm wider rear wings from CSP which dented the bank balance somewhat! Hopefully my Kafer 5 bar set up from vdub engineering will be ready soon too! its all starting to come together :D

anyways more pics! Ally spacer blocks for the beetle mounts


blasted 944 turbo a arms - not sure whether to leave them bare - paint them, powdercoat them or anodise them. ive left an ally springplate cover outside to see if it oxidises


powdercoated goodies :) still awaiting new bearings/bushes etc from pelican parts before i can put it all back together


996 caliper and rotor. 944 front hubs and cb performance dropped spindles away for machining.

finally a nice upright oil filler for my type iv motor build!


offically started prep on my doors yesterday after removing the worn hinge pins. its going to be a slow process but it hsould be worth it!

January 24th 2010, 21:49
Looking great...it will all be worth it in the end (thats what I keep telling myself anyway :rolleyes::lmao: )

January 27th 2010, 10:44
Who are doing the work on the hubs and spindles?

Cheers Steve

January 27th 2010, 17:42
a friend of mine who works in letchworth :)

January 28th 2010, 07:15
a friend of mine who works for chasestead in letchworth :)

Does he want another set to do? ;)

January 28th 2010, 17:19
i'l have a word. i havnt managed to get a fixed price from him yet. what hubs are you using? i dont know off the top of my head but are all bearings the same for 944s?

January 29th 2010, 05:23
Using early Turbo hubs (1 year only) and turbo 4 pots. As far as I remember the 944 bearing sizes are the same but spacing between may differ.

January 29th 2010, 06:05
anyways more pics! Ally spacer blocks for the beetle mounts


Carefull with those protruding bolt heads in your tranny bellhousing. They _may_ just hit the flywheel ring gear...

January 31st 2010, 06:22
Carefull with those protruding bolt heads in your tranny bellhousing. They _may_ just hit the flywheel ring gear...

thanks for the heads up wally. i will be using countersink bolts though as i said :)

yesterday my gearbox blocks to mount on the beetle cradle turned up and they work nicely :) i just need to get some countersink bolts but this is it mocked up.

this week i made several purchases that i probably shouldnt have as i'm fairly skint at the moment lol! my CSP wings turned up :D along with my order from pelican parts so i can now build up my rear arms. i also won a pair of 2.0l cylinder heads on ebay very cheap, and some 96mm barrells and pistons.

also this week i changed the door pins on my passenger door, prepped both doors and rear valance and got a coat of reface on them so im pretty pleased :)

January 31st 2010, 08:56
Oeps, must have read over that part...:o
Well, better safe than sorry ;)

February 7th 2010, 13:48
ive dont a bit more on my bug - but mostly filler work which is dull as fcuk! and messy....but gota be done....especially as i want to to be as stright as an arrow!

both doors and rear valance are now in reface




and the passenger door has new door pins

i noticed my origional door has an audi logo on it - shows how late it is :lol:

decklid received the swiss cheese treatment also and is now ready for reface



quick pic of the barrles and pistons....anyone have experience of the aa stuff? is it any good?


also turned out the 2 litre heads i won on ebay were 1.8 heads.....which is nice!

February 7th 2010, 13:50
also had the boxster S rear discs opened up to sit on the 944 hubs


discs have gone off for powdercoating.

also rebuilt the a arms with new bearings etc and put together the spring plates with weltmeister bushes





slowly but surely making some progress :)

February 7th 2010, 17:25
how bout those Boxster discs at the rear. What it means "opened up".

You mean inside, so You can fit them on to the hub?

Cool project by the way 8)

February 7th 2010, 17:33
yeah the hole in the middle has been enlarged 2mm iirc - to the same size as the 944 disc so it sits on the hub in the correct position (if you look closely at the hub there is a raised ring)


February 7th 2010, 17:35

Does OG 944 4-pot caliper fits perfectly, or You've made some spacers, or You don't use them at all?


February 7th 2010, 17:38
il be running 996 rear calipers (same as boxster S) but the disc is the same diameter and thickness as the 944 turbo disc - however i think the offset is slightly different but again only a couple of mm so may require spacers for 944 tubro calipers

March 13th 2010, 12:45
well ive been working on the chassis this week to get it finished. ive shamelessly copied a couple of ideas off of another project build on here but as it ws one of the neatest installs ive seen it seemed silly not to!

The rear mounts worked a treat but needed 8mm spacers between the framehorn and cradle



and this is the front mount welded together


which was then trimmed and neatened up



the shift rod was shortened 20mm


and the underside of the chassis was closed up similarly to the other project build.



Framehorns were clearenced for the Larger CV joints


and kafer bar set up mocked up and the tabs welded in


i only had 1 short and 1 long bar to do this as the rest is still being made


i also ran the fuel lines



its off to the blasters and powdercoaters next week, then the obttom is being gravitex'd and painted black (over the powdercoat) then i can start to think about building it up!


March 13th 2010, 19:17
really nice work man...:)
keep it up love the welds and fab work Super Clean :thumbup:
keep the pics coming

March 13th 2010, 23:27
Nice MIG welds! Love the install so far...keep it up! This forum is for helping everyone with their projects. :)

March 14th 2010, 04:00
Thanks for the comments guys :)

wrenchnride i dont think it would have been quite the same if i hadnt seen yours :lol: you've definately helped me!!

i'm already thinking about going over to the porsche coupling instead of the beetle coupling lol!

i wont be doing any work on it for a few weeks now as im moving house and changing jobs in the same week.....but when the chassis comes back il build it up and get it rolling - the body is booked in for paint in 10 weeks and i rekon ive got a couple of days tieing up lose ends on that before shes ready to go!

thanks again


May 19th 2010, 17:13
Well with starting a new job and moving house theres not been any progress to speak of over the last couple of months, but today work started again, heres a sneeky peek of the rear end....


ive got my motivation back :D

im going to dry build the car before paint - and ive got some mods to make so the paint date has been moved back a bit!

May 19th 2010, 17:33
Cheeky shot, nice rear end you have there!


May 19th 2010, 18:35
great work so far, I like your project alot. I just put your photobucket account on follow :D Please keep the gearbox install pictures coming, I'm very interested, because I'm right behind you, having aquired a 915 gearbox :D

May 19th 2010, 21:24
Looking good! :)

May 21st 2010, 18:27
Thanks for your kind words everyone :)

hoping to upload some more pics tomorrow!

June 10th 2010, 16:09
made some progress but its mostly been saturday work....which haven't been that productive as we've had a couple of bbqs at work and ive just got a mk2 golf that im tryin on the road as a daily!

but here are a few pics

managed to get a porsche coupler and rod which ive spliced with the beetle shift rod - will be able to make fine adjustments for shifting now! i also installed new bushes


fitted hi pacs - quality products!!






welded up the holes in the moon vent and ground them down with a dremmel - it was a right bitch of a job - also welded up all the holes in the firewall and ground off the tages for the old tar firewall.



also fitted the rear valance, wings and decklid and spent a couple of hours fettling making sure it all aligned properly - need to get better pics of the valance though to show how ive done it.





mmm bbq


June 10th 2010, 20:00
Looking good. Keep the pix coming.

June 11th 2010, 14:53
That Barby looks good tooo!


June 12th 2010, 16:57
Thanks guys....you can see why i became destracted then :lol:

done a bit more

boxed in the boot floor - tried to replicate the pressings using the bead roller!





Phatbug03 was kind enough to let me borrow his case and fan to mock up......and im glad to say.....IT FITS :D decklid shuts with no probs!



his is a early 911 fan and mine is a 964 fan but i doubt it will make any difference. ive got some better pics with the decklid shut - showing about 30mm of clearence

June 12th 2010, 16:58
i also removed the bonnet seat strips off of the front - and cleaned the rust underneath.




and been teaching the misus to weld! shes doing pretty well!


June 15th 2010, 12:00
nice project!, more peeks!

July 4th 2010, 11:08
thanks ragtop81 :)

here are some more pics!

ive done a little more, test fitted the doors, front wings and bonnet!



it all lines up pretty well although i do have an issue with the bonnet sitting slightly proud in the middle which is a little odd as its a NOS genuine item. im going to fit another bonnet this week to see if its the bonnet of scuttle but im sure i can tweak it a bit to get it to fit.


welded up the radio hole and the old drain area by the fuel tank


then i took off all the wings again and unbolted the chassis so i could get the shell on tressels to spot weld on the bottom plates



i also finished off the welding on the fornt bulkead, and the 1/4 strengtheners that attach at the back of the front clip



I also took a couple more pics of where i boxed in the boot floor for the 915 gearbox - underneath





a couple of hte chassis almost finished - i just need to change some brackets for the brake lines and re route the throttle cable tube




i also won these 996 rear calipers on ebay for half the price i was willing to pay :D

i was a bit miffed when i received them though as they were suitable for 986 discs instead of 996 discs (4mm thicker) so i pushed the pins back to where they should be which was more effort than i thought it would be.





ive pished each pin out by about 3mm

theyl be refurbed and mated to my 944 T a arms and 996 rear discs with an ally adapter


and now the bugs back on its pan again


ive got about half a day of tieing up lose odds and ends then its ready for prep and paint! whoop!!! :D

July 4th 2010, 15:38
Great job on the calipers! I never thought of pushing the pins outside, good solution. How did you actaully do that as you can't just hammer them from the other side..?

July 4th 2010, 16:06
Thanks, i used a large G clamp - and a thin peice of wood to i didnt damage the face of the caliper. i gues i should really drill out the roll pin - and replace it.

i am a bit confused why they were wrong though - the part number is a 996 rear caliper part number - but the pins were 23/24mm apart - so i gues they were used on the back of a normal boxster (20mm disc) not the boxster S. strange one.

July 5th 2010, 21:16
Looking great so far! :)

July 6th 2010, 01:15
Wow! Awsome car! Great prgress!

October 29th 2010, 06:24
Thanks for the comments guys!
well ive not updated this for a while because ive mainly been rubbing for 2 months lol! Ive been prepping the car with my mate craig who's going to paint it for me. so far i rekon we've put in around 200 hours which may sounds like a lot but we;ve gone to pretty good detail inside and out. All the leading and filler work has been done and the car is now im primer (no pics yet), which now just needs wet flatting and the booth is booked for the 13th Nov, 2days before my birthday :D anyways here are a few pics!








i also finally finished my chassis which is going for blasting and powdercoating next week. i had to set where the shift rod attaches to the gearbox so i could get all gears smoothly and drill the dimple which wasnt easy! that metal is real tough! i also had to change a couple of brackets for the brake lines



ive also been buying all the little bits i need to build the car up including all rubber items! these are my favorite things, new genuine bonnet handle, rear catch and hella light rims.


ive been trying to get new genuine door handles but dont seem to be suceeding. i think il get my old items rechromed but they do have some light pitting.



Ordered up my fuel lines and clutch lines


so yeah its all starting to come together. the last two months have drained my will to live, and my bank account lol - i just hope its worth it!

November 13th 2010, 12:11
il keep this short and let the pics do the talking but this my my day trip to BMW specialist cars today!

530am my alarm went off and by 630 we were ready to go!











November 13th 2010, 12:12







November 13th 2010, 12:13










November 13th 2010, 12:16








November 13th 2010, 13:30
that is soooo nice :D:D:D

November 13th 2010, 18:42


November 13th 2010, 22:07
Thats very nice. Now for color sanding and buffing in American terms, and flatting and rubbing out in English terms :D

Steve C
November 14th 2010, 03:16

Your car is looking good, I may have missed reading it. What colour did you paint the car?

I'm pretty sure I'm going Porsche Blood orange (that's this weeks colour LOL) your car colour looks similar.


November 14th 2010, 05:30
Looking good. Very nice color.

November 14th 2010, 06:09
thanks for the comments guys - i cant stop smiling!!!!

the colour is the origional L30M Tomaten rot (gt beetle colour)

Craig did a fantastic job of putting the paint on - a good flat and polish - as you guys have said - and it will be like glass :D

December 10th 2010, 14:38
not a lot to report - waiting for my chassis to come back from blasting/coating (ABS blastic/Perfect Coatings Bedfordshire) before i can really get stuck in building it up! The bolt on panels are on to get them out of the way! Started building the doors up and dug out my mint condition padded dash from under my bed




have had some nice rear caliper brackets made up front ones are in the process of being done. 944 front hubs have been machined for my dropped spindles.





and a pic of some of the stuff thats just come back from being coated



had a few geuine type iv rocker covers coated.

keeping a couple of sets of myself but may sell some if any interest


and my steering wheel which will match my dash pretty well. as far as i can tell its pretty damn rare. ive tried searching the internet to find more about it and only found a couple of threads of people tryin to find more out about them lol


some progress is better than no progress

if anyone is interested in having some 996 caliper brackets made for 944 turbo arms with 996 discs please let me know as i may have a batch made if there is enough interest



December 21st 2010, 17:14
Not a lot more progress- but something is better than nothing!

Had a trip to my local friendly second hand parts suppliers who supplied me with 2 battered seats ive stripped just for the subframes. these will be mounted to my 996 seats over christmas as the seats are at my parents!

I also obtained a great condition speedo. I wanted to return the clock to zero, as the car will be basically brand new - thanksto julian for the tips


Speedo in many peices



this is the drive that needed to be disconnected so i could wind it


looks brand new again!


couple pics of my dash im UBER pleased with. Its proper mint! the only thing i had to do was repaint the speedo bezel bit. Fitted two rocker switches for heater front and rear screens too - tried to make it look as factory as pos.





Then tonight, thanks to julians little box of levers, i rebuilt my door locks to match my VW key for the rear lid catch


just gota do my ignition barrel now, which, after some research, is a feckin ball ache to remove from the housing as i have to drill a hole to get to the retaining clip - vw thought it best to omit this hole for some reason?!

AND MY CHASSIS IS FINALLY GETIN COATED!!! WHOOOOOOP!!! popped by perfect coating this evening - it should be black by tomorrow!





it does have some holes though ... when this comes back to me il repair it and touch it in.


hopefully il make some good mprogress before the new year!

December 22nd 2010, 14:36
just gota do my ignition barrel now, which, after some research, is a feckin ball ache to remove from the housing as i have to drill a hole to get to the retaining clip - vw thought it best to omit this hole for some reason?!

That hole was omitted so that your car couldn't easily be stolen...or so was the theory.


December 30th 2010, 14:59
Dave, thanks for the reply. It appears VW put the holes in some castings - im not whether its the earlier or later ones though. I ended up using another casting as a guide.

December 30th 2010, 15:02
Also managed to get the ignition lock working on the VW key i wanted so all locks are now done :)

December 30th 2010, 16:11
Chassis came back from powdercoaters (Perfect Coatings, Beds)




Which then got Gravitex'd and painted 2k black







Blew off the cobwebs on my suspension stuff and started the rebuild. 944 Turbo arms and torsion bars – fitted with swan necks for the handbrake conversion and 996 discs.





Swan neck fitted up to handbrake cables


Handbrake fitted up


Tilton set up fitted

Then started on the Hydraulic clutch. Got an adapter t piece from npt to jic for the Goodridge lines im fitting.




Which was then coupled with the pedals – kinda hard to get a pic of it



The line exits out the clutch cable conduit

Fitted the fuel feed line and return line

bug@5speed shifter fitted with shift rod also.


December 30th 2010, 16:17
And cleaned up the rear brake unions so they look new again! ( Thanks to pruplebug for one of them!)





So that’s as far as ive got so far on that

Ive also fitted up the 996 seats to the beetle subframes by welding on some tabs





Also painted my gearbox painted, but ive just figured out I either need to get a different box, or strip this one to have the throw out bearing guide tube milled down (martin bott suggested this) so I can fit the bug@5speed conversion tube. Pretty gutted as I didn’t really want to do that and stripping the box looks like hassle.

Done until next year now. have a good new year everyone!!!

December 30th 2010, 20:48
Wow! I gotta get moving on mine! Hey... those are my seats! :lmao:

Looks great!

December 31st 2010, 05:32
Nice work!

Your sure those are the (wider) turbo arms though? They seem to have the shorter outer nose (?)

December 31st 2010, 06:19
Thanks guys :) wrenchnride stop working on other peoples cars and get yours done :p your motor looks ace btw!
Wally - you are right they are the narrower turbo arms.

Wally on a scale of 1 to 10 how would you rate the difficulty of stripping down the 915 box? I've never done a box before.



December 31st 2010, 07:00
There is no such thing as a 'narrow turbo arm', but hey who cares :D

Just taken a 915 apart is really not that difficult in hindsight, you just need to overcome a barrier with yourself. Its more psychological than mechanical really ;)

You do need a good manual/parts sheet to get starting though.

December 31st 2010, 07:59
taller disc then lol. Cool, i think it just seems a bit intimidating if that makes sense. I read a rebuild thread and it looked straight forward but i gues you never know until you give it a go!

January 1st 2011, 07:10
There is no such thing as a 'narrow turbo arm', but hey who cares

The arms are all the same thatīs true,but there are different hubs.The S2 Turbo hubs are wider.:D

January 8th 2011, 17:02
Right more of an update. fitted up the front fuel line fittings which was a pain and gave me a blister lol!


mastercylinder painted and fitted. thinking about mounting the linelock here or bulkhead.


i got my brake lines made up.





body rubber hole punched and fitted


Fitted up a temporary beam that was on the shelf – it appears it has no beam bearings and the torsion arms properly waggle around lol. Managed to get a second hand beam im goin to narrow to use until I get round to making one


Then yesterday I got the body on and bolted it down today. Im WELL pleased :D I feel like I did when I first bought the car when I was 17!!! :D













January 8th 2011, 17:40
Really, REALLY nice, well thought out, can't wait to see her together.


January 8th 2011, 23:16
Moving along very nice! I hope you plan on putting some sound-deadening in before interior is fitted though. ;)

January 9th 2011, 20:27
2 thumbs way up bro :D:D

January 9th 2011, 21:04
The Tilton piece, mounted on the tunnel by the shifter, it's a staging brake?

January 9th 2011, 23:45
That would be a brake-bias valve. Used to adjust the balance between the front and rear brakes.


January 10th 2011, 07:30
Very nice. Love that color.

January 10th 2011, 08:54
Very good & clean Job!!! Keep up the good work!!

January 11th 2011, 03:11
really clean! :)

February 5th 2011, 13:05
Thanks again for the comments guys!

My bug went for its headliner last week! Pete @ delux has done a few volksworld cars and is awesome with a sewing machine :p

it was the first time its been out of the workshop bolted together and polished so i took a few pictures!







paint work looks awesome - just a few things left to do on it now!

also picked my brakes up today :D





Just need tp paint the hub, spindles and calipers now :D

February 6th 2011, 20:29
Absolutley SICK!!!! I will be following this thread to the end. Well done and keep up the great work. Learning a lot, thanks for sharing:)

February 6th 2011, 21:51
This Dub is looking amazing! :)

February 7th 2011, 10:19
It looks awesome! Was it hard to machine dropped spindles to accept those brakes or it was not an issue? :D

February 7th 2011, 12:37
Bright red paint, big @ss brakes. I love it.

February 9th 2011, 15:01
thanks again everyone - you're comments have spurred me on to get it done! mx67 bearing adapters were made to run beetle bearings on the spindle. a few mm was taken off the back of the hub, and a small area of the back of the spindle was spotfaced to create a flat face to mount the caliper bracket. then a hole was just drilled and tapped to bolt the bracket on :) it sounds simple but did cause a couple of headaches regarding the best place to put the caliper ad best way to mount it.

got my car back from Pete today and he's done a great job. It's REALLY hard to photograph the black headliner on a bright day against a birght colour so the pictures dont really do it justice!







il get the windows in next week :)

February 24th 2011, 19:16
Ive got my wiring loom in - just needs connecting up. all made from scratch using modern thinwall wire with a few extra wires for guages etc.




got my genuine front bumper fitted up and new hella headlight rims


NOS rear light back plates and hella lenses too!





February 25th 2011, 09:33
Looking good. Headliner came out great.

February 27th 2011, 12:45
You Suuuurrre you don't want to take those white items off,
Rear-view mirror, visors, rear cabin vents, etc,
And dye them black to match the headliner?

That white, just...

Nevermind me,
I'm here to pick nits!:D

(Pretty easy to tell who's the jealous one here)

February 27th 2011, 14:35
do ya think il be running dirty old white interior bits after the extent ive gone on this car ;) they were just put in holes to make sure thehealiner had been cut in the right place. al interior gubbins will be new black to match the rest :)

February 28th 2011, 10:17
Dean, for the rear view mirror, what are you fitting? A mk2f Polo one is a nice mod. They are a bit longer in the stalk and same fitting

March 1st 2011, 15:46
thanks for the heads up al - il check that out!

March 1st 2011, 16:28
Or in fact Mk2 Golf... http://www.eurowagens.com/en/vw/golf-2-jetta-2/interior/rear-view-mirror-vw-golf-mk2-jetta.html

March 1st 2011, 21:05
Very tastefull build. Solid parts choice and coming very nice. Engine details? Only thing not like is the black headliner make the interior looks smaller that it is, but that just my opinion.:)

March 4th 2011, 12:34
That black headliner looks cool to me. But I also agree interior now looks smaller. Anyway, You don't have to do roof chop to get "that" feeling :D

March 4th 2011, 20:06
I recently put a black headliner in my oval.
Makes the cab feel more cosy, like a regular car,
Not concert-hall cavernous like it does stock.

i remember my first ride in the back seat of a bug, and noticing how huge and high and round the roof was.
Wasted space, really.
if they weren't so damn hard to chop...

March 6th 2011, 04:59
each to their own i gues. i like the black as it goes well with orange and i wont be having a back seat so i gues that'l open things up a bit. i also wanted a more modern look as clatter says. a lot of the modern audis have dark interiors and i think they look ace.

ive done a bit more and the majority of the wiring loom is in. just have the headlight switch to wire up and then start tidying the wiring. :D

May 18th 2011, 14:12
Right....finally got to do some more work on it!!
Craigs polished under the bonnet and i finished the wiring loom.













Some of you may wonder why im using old VW connector plugs and uninsulated terminals. Basically i wanted to make the loom look like in belonged - original but slightly better. All the wiring is in standard colours with a few little extras. Ive added wiring for my guages (tacho, pressure, temp etc), ive added electric washer bottle wiring which works off of the wiper stalk, front and hear heated screens, lineloc and fuel pump. The fuel pump is wired in on a relay circuit so if the engine cuts out eg in an accident, the fuel pump cuts out. I wired in the original heated rear screen switch to work the pump when i need to prime the system before starting the engine ----> pic


and these two are my heated front and rear screen in place of the electric fan switch



and finally shifter with lineloc button (all the wiring hanging through the glove box is for guages)


i just need to decide what to do with these two holes in the dash


i was thinking about getting two hazzard switch knobs which light up - and changing the colours of the plasic so they look factory but can have one as a shift light and one as a line loc light

May 18th 2011, 17:26
I love what you did with the wiring! Everything is so nice and organised.. I tried to do something similar in the engine compartment for the last month. An I actually see some stuff that I used too, like that small 6-fuse box.
What is the part number on the fuel pump relay? I heard of those special relays after I did my relay panel, and saw one on CSP for 60Eur or something. But I think all the old fuel injected watercooled VW's have it too. Just gotta find out the number that should be on it. I saw that all VW relays have that big number on top of them.
Oh, and do you take the signal for the relay from the negative side of the coil? I wonder what I'd have to do in my case... maybe from the Megajolt tacho signal or something.

May 18th 2011, 23:46
What is the part number on the fuel pump relay? I heard of those special relays after I did my relay panel, and saw one on CSP for 60Eur or something. But I think all the old fuel injected watercooled VW's have it too. Just gotta find out the number that should be on it. I saw that all VW relays have that big number on top of them.

Factory part number 443 907 385 will work. Otherwise look up a relay for a 1985 Audi 4000 quattro. Part number may be different, but they are interchangeable.

http://www.rockauto.com/dbphp/x,carcode,1007592,parttype,3380,d,1985_AUDI_4000_Q UATTRO_S_2.2L_2226cc_L5_FI_B_JT_SOHC_Fuel_Pump_Rel ay.html

Relay Terminal | Description | Connect To
15 | Switched +12V | Coil (+)
31 | Ground | Chassis Ground
87 | Fuel Pump Power | +12V Directly from Battery (remember to add inline fuse)
30 | Switched/Fused Power | Fuel Pump (+)
31b | Trigger Input | Coil (-)

The circuit requires that the coil be in the circuit. Just applying 12V to the trigger input is not enough. The circuit relies on the higher voltage pulse that is generated by the coil. Not sure how you would use that with Megajolt. I have successfully used these relays in tonnes of cars, including a '77 mustang with weird Ford electronic ignition.



May 19th 2011, 02:18
The relays s just a cheap 5 pin relay. about £4 and heres the diagram - no need for the coil to be involved


hope this helps :)

May 19th 2011, 08:18
haha, that's ingenious! So as long as the alternator is charging, the fuel pump will work. Nice one!

May 19th 2011, 08:57
The fuel pump shut off has been a big item of discussion on the VZI Forum and DubCrazee's layout is one that is often used. Personally, I have used the low oil pressure light to swich the system as I once attended an accident where the car rolled, the engine continued to run upside down until it siezed! With the oil light switching oil pressure would have been lost early in that situation and the engine would have been shut down earlier. Also, under normal circumstances there is enough fuel in the carb(s) to fire the engine with the fuel pump switched on but if the pump is switched off the engine just runs for the duration of the fuel in the carb(s) and then shuts down. It needs then to be re-primed otherwise the pump won't work even when switched on with the oil light illuminated. All of this gives a real headache to any little thieving b*****d.


May 21st 2011, 15:48
Good point about the accident clive.....ive read the last bit of your reply and im not sure i quite follow though? im probably being simple

September 11th 2011, 12:12
Well it's been a while since ive posted - and to be honnest ive not got a lot further on. i've been very busy working on friends' cars and starting up my own business so it's been hectic! I've put my 996 seats in and fitted up black sun visors and rear view mirror which isnt exactly exciting but i will be ordering engine bits this month which is a step in the right direction :D also, i had this made......which some of you may like.....and others may think it's a waste of time as it's not following the function over form rule of GL....


i'm absolutely chuffed with it!

also, all of my calipers have been refurbed and painted.....and the front beam is off for some custom shock towers. once that's done the front end can be completely assembled and finished just leaving me with painting the gearbox and building the engine. deadline for completetion is last weekend in march (volksworld show)

September 12th 2011, 07:58
Nice touch.

Steve C
September 12th 2011, 08:33

I like the badge.

Regarding the fuel pump relay, I used a BMW one on my sons 1303, it primes in the start position.

Bosch relay PN# 0 280 230 001 (BMW 520i 1992) and have the following terminal information:

50: Start Signal (from starter or ignition switch crank position)
87: Switched 12 volts (out)
87b: switched 12 volts (out to pump)
31: Ground
1: negative side of coil (trigger to keep relay engaged - engine running signal)
30: +12 volts supply (switched 12 volts in )
15: +12 volts supply from ignition key

September 12th 2011, 20:05
Very cool Dean. How did you have that done CNC? Subtle is good.

September 17th 2011, 06:13
cheers :) yeah cnc machined. GT badges are becoming quite rare and a lot of money - i can get GT badges made if anyone wants one. (GT not the GTi one)

September 17th 2011, 17:22
Going back in time a little...

i also removed the bonnet seat strips off of the front - and cleaned the rust underneath.

Did you end up replacing them, or leaving them out? How are you sealing your hood?

-Dave (who's project is currently at the "do I remove the strips" stage ;-) )

September 18th 2011, 11:01
Use the bonnet seal that attaches to the bonnet not the slam panel.

The original metal strip for retaining the seal is a pita rust trap.

September 18th 2011, 13:56
Does that bonnet seal go around the top too? I ordered one for my 69 and it was too short to go all the way around the hood.


September 18th 2011, 14:54
no - i removed the old strip along the front scuttle - repaired the rust and then replaced the strip along the top - i had to buy the mexi seal (clip on one) and the standard one so i could trim it and use it along the top

September 18th 2011, 15:31
Thanks Mate!

November 9th 2011, 10:47
i started this project october 2008 - starting with a 1976 body and 1969 chassis. I started off with a 1976 beetle i had since i was 15 - and acquired a 1969 chassis to IRS.

a couple of pics before



First up was new heavy duty floorpans and IRS conversion with 944 Turbo a arms





with this being shoe horned in next!


The chassis has also received a couple of small repairs to the framehead, a hydraulic clutch set up a a bug@5 speed shifter





the clutch MC was fitted through the inspection hole (had to be slightly enlarged) and a hole made behind the throttle lever arm cover for access



i think this is a much better way of installing it rather than cutting a large hole in the top of the tunnel as suggested :)

have you got any more information about the hydraulic clutch installation.

November 9th 2011, 12:17
Pretty sure its a SACO unit that Deano has.

As per usualy I'm looking into MCs that will work with my current CNC slave and in future something else.

November 20th 2011, 09:20
yeah Al is right its a saco unit. still havnt decided how to mount the slave - i will come to that soon!

Well i haven't made a whole load of progress over the last 6 months - but hte progress i have made has been pretty cool imo :)

I've put my 996 seats in and fitted up black sun visors and rear view mirror which isnt exactly exciting but the front suspension has come on abit . The beam was narrowed 80mm back at the begining of the year but i wasn’t happy with the shock towers. I decided to design my own link pin style ones and have them made out of 8mm thick steel. The beam is now finished and together along with the refurbed brakes


Gearbox, steering box and track rods need painting - wheels are going to be refurbed just leaving the interior. The car has been booked in the the trimmers for Jan. The conversion flywheel is currently being shipped from the US and then the engine build starts. Th countdown to VolksWorld show has begun!!!!

November 20th 2011, 09:21
oops the pictures are huge! need to change it lol

February 12th 2012, 16:14
Well i picked up all the bits for my type iv tubo engine build and they now reside with rob RNJ motorsport.........i'm very excited about having and bug running again after 4 years :D

March 2nd 2012, 18:05
well the deadline is coming around TOOOOOO fast with only 3 weeks to go until volksworld!!!

I've finished the brakes which are now all bled up - and the hydro clutch is fitted although does have a small leak i need to sort. We'l be spending all weekend at the bodyshop redoing a couple of bits im not happy with and refurbing the wheels and Rob is building the motor as we speak. i'm hoping it will all come togther very quickly!

just a quick run down on the spec of the motor

96mm JE Pistons
hardened eurorace barrels
Webcam turbo grind
case bushed for type1 lifters
55g super vee lifters
5 dowl 71mm crank
kennedy 915 conversion flywheel
H beam rods
dry sump match ported to case
CSP python exhaust
manton cu to length push rods
1700 rockers
44x38 square port heads, stainless valves, cromoly retainers, LS650 springs, 55cc chambers
porsche upright cooling

it'l be run on carbs for the first year unutil my bank account recovers and i can switch over to efi turbo

im getting rather excited now :D

March 4th 2012, 10:37
Sounds nice. I would be excited too.

March 5th 2012, 15:31
the bug is back now after being at the paintshop with craig until 430 sunday morning redoing a couple of bits i wasnt happy with and refurbing the wheels - pretty happy with how theyve come out!



glad i went black caliper rather than red :)


March 6th 2012, 13:10
Looking forward to seeing it at ride height for the final look, wheels look good!

March 8th 2012, 14:31
Really looking the biz!

March 8th 2012, 15:55
Very nice!

Mr Big
March 16th 2012, 20:30
I like your shock towers. Been trying figure out something like that myself. How are they working out?

March 19th 2012, 17:22
dunno i;ve not driven it yet lol!!! It's similar to the slamwerks beams (although mine is thicker!) and can't see a reason for it not to work. If i was to change it - i;d make the top mounting point about half an inch towards the rear of the car as the shock isn;t 100% vertical (pretty damn close though)

March 20th 2012, 10:36
Cool just read through the thread looking good, Volksworld friday.....!!!!
see you there!

March 27th 2012, 15:01
Well my bug made it to the show :) Had a great weekend - met some great people and the sun was shining aaaaalllll weekend! :D

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/535040_399302850097828_100000543484687_1398639_221 71378_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/522583_10150631917172097_668462096_9752374_1919386 636_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/s320x320/550866_10150606997571825_552856824_9432804_1000794 223_n.jpg

March 27th 2012, 16:36
good to see your car at the show mate it looked sweet,shame mine never made it hopefully next year.do you use those plates on the street ?

March 30th 2012, 16:55
Thanks mate,

yeah i do plan on running the plates on the street - we'l see how many fines i get as i may change my mind rather quickly!! :lmao:

June 9th 2012, 15:03
will ive made a bit more progress on the bug and is ALMOST ready to MOT......but the bug obviously wants to stay off the road a little longer.....

all the oil/fuel and breather lines are done - just need tidying






just need shocks now and engine setting up by RNJ Morotsport.......however the bug spat its dummy out last week

the new hydraulic clutch set up (although is now 4 years old as the project has been going on for so long!) decided to ditch all the the fluid inside the tunnel of the chassis :( ive flushes the tunnel as best i can and looks to have got away with minimal paint damage. I took the cylinder out (which it turns out i can only JUST manage with the body on!) and is scored.....so have ordered a new updated kit from saco performance.....which will be with me in 2 weeks!

soo now its just clutch and shocks......... :)



lets hope its ready for spa!!!

June 9th 2012, 15:51
It sure looks extremely nice!
Deffi hope to see you at Spa!

June 10th 2012, 04:08
Very nicely done! I love the wheels and color combo! An almost perfect clone of the license plates too.

June 10th 2012, 11:24
Looks awesome! Question: What axles did you use with the aluminum trailing arms?

June 11th 2012, 03:19
Thanks guys

I will definitely be at spa, hopefully in the bug but if not, il be in my 70 bay. Il keep an eye out for you wally!

Axles are 944 items to match the arms

June 11th 2012, 03:41
looking good and looking forward to geting it in the workshop to fire her up and dial the motor in.

June 11th 2012, 03:51
Dean, did you just get the MC from Saco or a rebuild kit?

I keep looking at alternatives to the Saco for in the tunnel and they are not too common. BMW 3 series or one from CBSonline are my current choices. And if you don't mind me asking how much was it with post and tax?

Car is looking good fella, you'll be done soon and reaping the rewards of all the hard work :)

June 11th 2012, 14:44
Good to see the car close to completion. I know it has been a long road for you.

June 11th 2012, 22:24
Looking very good! Pity about the saco unit.

June 13th 2012, 03:18
Thanks for your kind comments again guys......it has been a long old road and a busy few years for me (not just with the car) just cant wait to be cruising around in it!!

it is a shame about the saco unit but after doing a search quite a few people look to have had issues with them. unfortunately saco dont do a rebuild kit for my MC a mine is one of the first ones and now they sell a cnc machined item (mine was cast) also the cylinder was lsightly scored.

lets hop their new kit last a bit longer!!!!

the MC alone has come to £117 shipped to the uk (il have duties on top of that)


dave forder
June 14th 2012, 13:36
The car looks great. I didn't go to the Volksworld Show, but I have seen the pictures of your car and it looked good. Love the picture of the engine. You can't beat the look of a Porsche fan. I hope to have mine ready for Spa so if you are there we will catch up. Got some updated pictures of my engine but can't get them to upload onto the site, shame.

June 16th 2012, 11:08
thanks dave,

would be great to catch up at spa...and maybe some of the other guys on here?! just seen the pics of your motor - it looks out of this world! Is marco buliding it? would love to pop down at some point as its only 20 mins from me!

dave forder
June 20th 2012, 13:10
The motor is not at Marco's but I would like him to have a hand in the final fire up and tune up. The engine is up at John Maher's and I hope to have some figures this week. Lot to do before Spa though. I think you have more of a chance of finishing yours in time.

August 15th 2012, 15:02
Well, i went to spa...but the bug didnt.....ended up going in my rustbox bay!


whilst ive been away the bug has been with rob at rnj motorsport.
motor is all set up - its mot'd but developed a couple of gearbox oil leaks........il be picking it up friday so il put some pics up!
i cant tell you how excited i am to have it back.....its been off the road for 3 years and 11 months (last time i drove it i took it to le mans)!!


August 24th 2012, 03:04
It,s on the road and great fun to drive!!! Going to have the gearbox rebuilt though as it has lots of leaks...... Which now means I have a lot of cleaning to do too!






Got a few other bits and pieces to do too ....... Are they ever finished?!

August 24th 2012, 04:02
glad your enjoying it and no there never finished as you will allways see another car and think yeah that would work on mine lol.

August 24th 2012, 04:21
Looks awesome! Maybe a little lower in the back, but other then that: georgeous!

August 25th 2012, 10:50
Hope you're happy Dean. Looks good, but I do agree with Wally. I'm not so into rake either

August 25th 2012, 13:51
Thanks guys. Yeah the back end will be coming down about an inch, maybe bring the front up half an inch, with a small amount of rake. A lot of rake doesn't suit German lookers IMHO. Want to run some spacers on the front too. Got to fit my gauges and make some rear tin over the exhaust. Hoping to make it to the Volksworld 25 year anniversary party at brands hatch!!

August 26th 2012, 22:00
Looks great. Get it dialed in and it will be a great ride. Glad to see it is on the road.

September 13th 2012, 03:03
Kinda bad news - i need a new nose cone for my gearbox.

so if anyone has lot a nose cone for a porsche 915 gearbox - or knows where i can source one please let me know.

ive phoned a few placecs in the uk with little luck - i also have bears and another friend on the case. Found one in the US but if somone europe/UK based has one please let me know

really wanted to have the car back on the road for the Volksworld 25 year anniversary thing at brands hatch but cant see that happening now :(


September 14th 2012, 22:04
Martin Bott has conversion nose cones...

September 15th 2012, 03:57
whats up with it? can it be repaired?

September 16th 2012, 06:09
Paul @ Bears phoned me on Friday - he's managed to source one for £250.
Not a bad price i gues - i was going to get one from Martin for $400 (he had an OG one - not conversion one on the shelf)

Rob - gearbox is a funny one. Paul said it looked like it had a very recent rebuild and the internals were in great nick. however, the nose cone had a crack and had been welded but also the bore in it had become ovaled (same in the intermediate section) so didn't have a reference point to sleeve it.

Now he's got a nose cone to take a reference from he can sleeve the intermediate section and put it all back together.

Fingers crossed he'l have it ready for me by wednesday morning. I'l give you a bell on monday re engine.


Mr Big
September 17th 2012, 18:34
Hope you get it sorted it mate. Still no progress on mine :(

Trying to find someone to machine the Porsche hubs for me. Can't do anything without them.

And remember, if you ever want to sell that reg plate ;)

October 14th 2012, 05:06
If you dont find anyone to do your hubs give me a shout and il get it sorted. :)

Finally got the gearbox back from bears and everything is back in and running

ive got a few bits of finishing to do - but nothing major. ive raised the front half an inch and lowered the back about an inch. i might lower the back a tad more - havnt decided yet. next step is rolling road although ive got my eye on some jenveys :lmao:

December 11th 2012, 15:50
Deano, I remember this car from a long time ago 2005?

Have you finished it yet?

December 11th 2012, 16:43
Hey matt!
Long time no speak - hows your bay doing?

Dont think they are ever finished are they??

Ive recently lowered the back a tad more. Clutch started slipping a tiny bit last time i was out in it though so looked like ive got to pull the motor again! Still got a few other bits and pices to do but its 99 % there :)




December 12th 2012, 05:26
We aren't ever finished are we.

Matt how is the house move going - you sorted somewhere now.

Dean, looking good as ever ;)

January 4th 2013, 16:08

what kind of hinges are they? Where can I buy one?

Steve C
January 4th 2013, 17:24
what kind of hinges are they? Where can I buy one?

Early Beetle dipsticks work well but are not a sexy as those ones

January 5th 2013, 16:20
Early Beetle dipsticks work well but are not a sexy as those ones

But i want sexy :cool:

January 5th 2013, 17:33
Here in North America they are known as a "linch pin" or "PTO pin". They're simply a locking pin with wire retainer. I've been meaning to do mine since I built the car...one day I'll get to it!

http://images1.mcmaster.com/Contents/gfx/large/98480a013p2-b02l.png?ver=16728517 http://images1.mcmaster.com/Contents/gfx/large/98416a120p2-b02l.png?ver=16728551


January 5th 2013, 20:16
Bogara in Europe you can find them online here
http://www.csp-shop.com/cgi-bin/cshop2/front/shop_main.cgi?func=det&wkid=18445501378&rub1=Body&rub2=Mechanism%20and%20Locks%2CBug%2CHinges%20and% 20Locks&artnr=15522a&pn=0&sort=0&all=

and here
http://www.vwheritage.com/vw_spares_Deck-lid-pins-pair-Easy-removal-of-deck-lid-AC827000_act_shop.product_pID_150529_lang_EN_count ry_GB.htm?crumbStartPage=2&crumbStartRow=31

January 6th 2013, 17:23
I got mine from VW heritage- simple idea but make life so easy! couple that with a removable rear valance and Hi Pac access panels - engine removal is a breeze!

ive seen some people make their whole rear end removable but im really not a fan of chopping the rear body work around THAT much.

January 7th 2013, 10:08
Bogara in Europe you can find them online here
http://www.csp-shop.com/cgi-bin/cshop2/front/shop_main.cgi?func=det&wkid=18445501378&rub1=Body&rub2=Mechanism%20and%20Locks%2CBug%2CHinges%20and% 20Locks&artnr=15522a&pn=0&sort=0&all=

and here
http://www.vwheritage.com/vw_spares_Deck-lid-pins-pair-Easy-removal-of-deck-lid-AC827000_act_shop.product_pID_150529_lang_EN_count ry_GB.htm?crumbStartPage=2&crumbStartRow=31

Thanks for the info & links!

January 7th 2013, 17:52
I prefer quick-release "Pip" pins. The ones I used are 1/4" x 3".



January 18th 2013, 13:47
Just received these in the post :D


retaining the torsion bars for now and running 175lb springs.

Also, after getting abit of clutch slip last time i was giving it the beans, i decided to investigate. Ive narrowed it down to the pressure plate :( that teaches me for not buying a new clutch! Just been to my local supplier who were the cheapest i could find at £290 :(

Well those jobs will keep be busy for a little while! Bring on the spring - i cant wait to get back out on the roads!

January 18th 2013, 16:58
Good looking alu-bodied coil-overs!

January 19th 2013, 05:41
Yup, good choice :D

January 19th 2013, 08:27
Lets hope they ride as good as they look :D
One thing I've noticed is they don't seem to have a method of locking the bottom spring platform. No lock ring or grub screw, which seems a little odd. I went for the narrower spring 1.9" but still do up to 500lb springs which gives me plenty if scope for uniball in the future if I with to do so. Very good service really and were on my door step in under a week. Prices have gone up slightly, these were a shade over £300 to my door but still seem good value for money! Il let you know how I get on

March 22nd 2013, 08:21
Thought I'd post a little update!

My hydro clutch went......again!!! So I removed it to find a few small score marks and a trashed seal...nice! So I completely sacked it off and managed to get a clutch cable tube from a 50's chassis a friend was scrapping! I now have a fully operational cable clutch :)

Also I took it to the rolling road as it was a bit rough low down. Went up a size in idle jet size has made so much difference, it's lovely to drive! It also made a very surprising 148bhp at 4800rpm!! Nt bad for a turbo spec lump! Can't wait to get efi and turbo on it!!


Hopefully il be going to lots of shows this year, I've booked 3 track sessions at apex festival and hoping to go to EBI too

Roll on the summer!!

March 22nd 2013, 08:42
Nice dyno result! Matching with the turbogrind's low duration and relatively high lift.
Weel done.

But...shouldn't you be at Volksworld show by now? (that was the plan iirc?)

March 22nd 2013, 09:30
Cheers wally, very pleased with the result! Thanks go to rob for assembling the motor!

The bug was on display last yet at the show so didn't put it in this year, don't want to bore people with te same cars every year!!
Looking at our weather forecast I don't even know if il go this year!!

March 22nd 2013, 13:09
Not good to hear. But at least it is all now up and running :)

By chance you don't still have the MC mounting plate do you?... I've just bought an MC to go in the tunnel but it might be useful for mocking up a mounting bracket :)

When are FI and a turbo becoming reality?

March 22nd 2013, 16:26
Al, unfortunately I am still using the mounting plate as it has the captives in that hold the pedal cluster in place. What mc have you got??

March 22nd 2013, 16:28
Oh and hoping that efi and turbo will be next winters project! I know speedshop are halfway through designing their set up but if that's not on sale in time think ilgo the jenvey route

March 22nd 2013, 18:39
Its one of these http://www.cbsonline.co.uk/product/Brake_Master_Cylinder_Kit__0.750%22_MAK750 3/4" and it'll mount in the tunnel. It looks very similar to a Wilwood kit that is available but I won't know till I get a look.

To be paired at the moment with a CNC slace. I was just after being lazy with some measurements really, fabbing a mount from 3mm plate shouldn't be difficult once Ive got some in there.

I see speedshop have released some more throttle bodies too, though I don't know how recent it is. I'm really impressed with their stuff and its excellent value once the price is factored in, certainly in comparison to Jenvey.

March 23rd 2013, 04:29
remember the best way for turbo is a single throttle body, no real need for itb's
Nice numbers on the dyno, always good to see how they perform as until its on the dyno and makeing power its all just theory.

March 24th 2013, 06:09
Al that kit looks like a decent alternative and fairly priced too!! I may go back to hydraulic at some point as cable is heavey!! We shall see! Speedshop have just had more throttle bodies made (cast this time) with injector bosses....but that's as much as I know so far! A lot of the stuff is made at a machine shop in hitchin not far from us.

Rob, I gues theory only gets you so far a every engine is different, I am hoping to achieve around the 220 mark with turbo. Point taken about single throttle body! However twins look soooo cool haha. Il start planning my set up after the inner and doing more research I think.

March 24th 2013, 06:40
I see speedshop have released some more throttle bodies too, though I don't know how recent it is. I'm really impressed with their stuff and its excellent value once the price is factored in, certainly in comparison to Jenvey.
I was actually more impressed with Speedshop's design then I was with the Jenveys design/quality after several years of N/A and turbo use...

And thats even before price considerations.

So hopefully he will get around making something for us T4 engine users. Fingers crossed.

March 24th 2013, 10:48
Interesting stuff Wally - I'm always interested to hear comments like that when everyone else in the world seems to go straight to Jenvey when they need something. I guess they serve to bring FI to those people who have used Webers/Dells all their life.

Dean, I never really realised how heavy cable clutches were till my purchase of the Bora, moved my mum's Polo off the drive and was amazed how light the hydraulics make even a big diesel clutch.

May 12th 2013, 06:50
Well....i am a very happy boy this week!!!

7 page spread in VolksWorld :D



Apex festival next week so im giving the car a full going over this week......im a tad nervous!

May 12th 2013, 06:55
couple more pics from the shoot




May 12th 2013, 07:33
Congratulations, very cool!

May 12th 2013, 15:24
Very cool indeed and well deserved mate!

May 12th 2013, 19:59
Congratulations. You can be very proud.

May 12th 2013, 21:16
Yes! Very well deserved :)

May 13th 2013, 03:15
cool :D

May 13th 2013, 03:41
Nice work!

Steve C
May 13th 2013, 04:17
Well deserved recogntion after all your hard work

dave forder
May 13th 2013, 11:34
Great feature, well deserved. Great looking car. Also, thanks for the mention. It means a lot. See you at Apex. :)

May 13th 2013, 15:59
Thanks everyone! I am really chuffed with it :)

Dave - no worries, i was truely gutted to hear about your white germanlooker as it was what got me into germanlook in the first place! Hope to meet you at Apex??

May 14th 2013, 03:35
so thats at least 2 type 4 powered beetles at Apex :)

May 14th 2013, 04:43
It's going to be great :D got to do a few bits to it this week and give it a full check over!.....i hope the rain stays away...

May 23rd 2013, 03:00
Finally got some track action pics at Apex festival



quite a lot of body roll!!


I did one and a half sessions. On the second sessions i had 3 seperate occassions where people spun off right in front of me (2 bugs and 1 porsche cayman) and decided enough was enough i didnt want to risk any damage to the car (especially as the cayman showered me with gravel!) so yep im bit if a whimp but it was good fun to treat her mean ;)

May 23rd 2013, 12:12
Bought the Volksworld issue just for this article. Nice work. Definitely earned the spread.


dave forder
May 23rd 2013, 16:32
Yeah it was nice to meet you at APEX. It was pretty cool seeing a whole bunch of German lookers all lined up together. I will have mine running and out with you boys next time.

May 24th 2013, 02:17
Congratulations on the magazine feature mate .I think the pic with the reflection in the puddle is very stylish and as cool as penguins piss :D

May 24th 2013, 03:01
Thanks for your kind comments people - really enjoying smashing the miles on it! Did 500 miles last week :)

Dave it'll be great to see your car on track - hurry up and get it mapped lol

May 27th 2013, 05:56
Bought the Volksworld issue just for your car. Nice work. Respect to all GL type 4 engined cars.

May 29th 2013, 14:11
Thank you :)

May 30th 2013, 05:39
Just an idea really. Autometer gauges reminds me Cal looks, Resto Cal, etc, not GL for sure.
Replace them with Stack gauges they are a lot more "circuit racing" oriented.

May 30th 2013, 15:36
I completely agree, i'l be making the change when i go over to EFI and probably go over to digi guages :)

May 31st 2013, 11:34
I really like Speedhut gauges.You can style them yourself and they have a huge selection to choose from.Far superior in technology and quality to the Autometer gauges.Stack is excellent also,but there are other digital dashes fir example race technology that has more features and is much cheaper,also excellent quality.



June 2nd 2013, 05:37
Those speed hut guages rock!

June 3rd 2013, 05:20
Seeing them in person is even more impressive! The best instruments on the market in my opinion!

December 7th 2014, 14:02
Well, i did't get to use my bug much this year as i sepnt a month in California and the rest of the time i was either working or wedding planning.....but i did get to use my bug for the big day :)

https://scontent-b-ams.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10306622_534730429961398_3081752230772035547_n.jpg ?oh=714448424ddae75e1cfb71d36d8d4d7d&oe=54F94E67

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/p417x417/10522415_535847593183015_295994477984562837_n.jpg? oh=64e02e75cab366e6c181200383154a43&oe=5508CB53&__gda__=1426697594_b420faa306edbeb4c463994fc375a84 d

Although i now have our other dub to restore (71 bay) i have managed to get my hands on a VW speedshop efi kit!!

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10445550_589978734436567_4124588280121466824_n.jpg ?oh=6920067cd3cc1a3ce057e57c63ca8191&oe=551359A5&__gda__=1426082451_ae7d1e2e4166af6378d28ff39a45831 e

Just need to order up some fuel fittings and a wide band lambda kit and i can get it fitted! I am also considering a M45 supercharger rather than turbo! I love a winter project :D

December 7th 2014, 18:00
I am also considering a M45 supercharger rather than turbo! I love a winter project :D

Just I thought I'd throw my 2 cents in regarding the M45 supercharger idea, simply put, its probably not the best route. I have one for my 97 civic and its design is limited to roughly 5psi before it starts to heat the charge air excessively. They can be overspun, but this will eventually shorten the life of the blower assembly. When the rotors get hot they will start to eat into the wall of the case thus establishing new clearances. This sounds all fine and dandy except that now the blower will struggle to make boost under normal conditions. You can help keep the heat under control with the use of methanol injection, but boost numbers are still limited to the size of the rotor assembly. The best part is the immediate torque off idle, but the engine won't pull like modest turbo setup. Now the bad issues regarding the tuning, (I can only speak for the honda scene) part throttle detonation is a real problem even with an aftermarket computer and proper fuel setup. Not saying it will never work, but wanted to share some of the headaches I've seen with the M45. If possible, a centrifugal supercharger would be the way to go and something totally unique.

December 12th 2014, 02:41
Oh, my, I just love this car.
Had to re-read the entire thread again.
That's like the fifth time now...

Every time something else grabs my attention.

-Like the fuel lines.
Looks like you started with hard lines in the tunnel then switched to braided?
Is there a particular reason it ended up like that?
Say, a problem? or maybe mock-up?

I'm trying to figure out plumbing my car, and wonder if you had any wisdom to impart...

January 11th 2015, 07:46
Thanks for your input mrzed

Clatter - thanks :). I went through three ideas for the fuel lines including stainless and copper lines but settled for hose just for ease. Not had any problems and done over 5,000 miles :)

Probably not a suprise but i did not get a chance to work on my beetle over Christmas - but instead put all of my time into my bay project. I will start a thread in a bit.

July 27th 2015, 16:24
Been a while since I updated this.....

Well it's been good, bad and ugly!

Bad.......I had a lot of smoke coming from the breather system. Turned out rings and barrels were shot but rob managed to save the JE pistons!

Good......I managed to install my efi kit!

http://i1104.photobucket.com/albums/h334/classiccarrevivals/817a5dc0b56de16e5f186a39a32c178d_zps1locqusw.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/07a5a9e5c991da097ddc4b3d3a0fd67f_zpsmkn1wdsl.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/b3c0993b95da36bb7e983478df3243d8_zpszpfxrjs4.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/0cf6fcf7137f664b79ab79f87418c484_zps5loshrvf.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/2ca7af2df7d35ec1c30ca95b9cd80404_zpsw07ilqyk.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/c28f53425b45a4ab66e024241c5a375c_zps8q2oxlxy.jpg~o riginal

The ugly......I ripped off my cooler 200 miles from home

http://i1104.photobucket.com/albums/h334/classiccarrevivals/42f4abad42b1f6baef8060e8dfa50ac3_zpsguemyyf1.jpg~o riginal

http://i1104.photobucket.com/albums/h334/classiccarrevivals/93968e6ed2508ad93febe8aad70f289d_zpsohzc81eb.jpg~o riginal

Still tinkering getting things better and I've also started making my shopping list for turbo conversion this winter!

So.....any recommendations on turbos? I've been offered a Chinese t3/4 but not heard great things about the longevity if them

July 29th 2015, 05:39
I would spend the money for a good turbo like Garrett, Precision or Borg Warner. I would not risk putting a Chinese turbo on that engine. With a 2056cc a GT2871RS would work great or a GT3071 with a. 63 AR. They don't need to be ball bearing, a standard bearing will spool plenty fast enough so you can save some money there.


May 13th 2018, 13:34
So this happened! Just waiting for some bits
For the charge cooler set up and will be mapped next month! Also gone wishbone front end

May 13th 2018, 14:18
Very nice!
Awesome welding/fabrication!

May 13th 2018, 14:31
Nice Dean

May 13th 2018, 23:28
Very cool!

May 14th 2018, 13:52
Which front end did you go for?

May 17th 2018, 01:09
Thanks guys. Rolling road booked for 19th June so Iíll post back with some figures
I went with the red9 set up Ricola. I know itís not perfect, I know it has its flaws but this is essentially a road car and does what I need it to. Iíve been through several steering boxes now and Iíve not been happy with any of them so a nice steering rack and a comfortable ride is what I was after and exactly what the kit gives me.

January 14th 2019, 15:20
Well a lot happened between my initial Rolling road but long story short my engine got run up with my dry sump tank tap turned off (not by me!) anyway after engine rebuild and turbo rebuild we finally got some decent dyno time. The results were ok! 231hp at 6000 at 18psi. It was great fun to drive but as you can see in the graph it all came in very late (turbo too big). It also didnt take long to kill it, I dropped a valve seat after a few weeks of driving :( One thing I learned is that boost is addictive and there arent too many cars that can beat a beetle wtih that sort of power - BMW m4 couldnt make ground on me).

Anyways, my engine builder informs me that the valve seats were put in too tight and caused the ally to rupture and squeeze out the seat, So im now shopping for a pair of heads. Currently in talks with FAT performance.

Ive also had my turbo rebuilt with a much smaller exhaust housing (55 AR down to 38AR). Ive swapped out my coil, changed for a turbo smart waste gate and I have some other small changes Im making and hoping to get back on the rolling road before the spring!

https://farm5.staticflickr.com/4885/46018422624_ea906e6d60_n.jpg (https://flic.kr/p/2d7urMJ)Turbo beetle (https://flic.kr/p/2d7urMJ) by Dean Jones (https://www.flickr.com/photos/155782865@N06/),

https://farm8.staticflickr.com/7805/45827510515_0be6251ab5_n.jpg (https://flic.kr/p/2cPBYgD)Turbo beetle (https://flic.kr/p/2cPBYgD) by Dean Jones (https://www.flickr.com/photos/155782865@N06/), on Flickr

https://farm5.staticflickr.com/4901/46690297672_52889b117f_n.jpg (https://flic.kr/p/2e8RYQh)Turbo beetle (https://flic.kr/p/2e8RYQh) by Dean Jones (https://www.flickr.com/photos/155782865@N06/), on Flickr

January 14th 2019, 15:50
Dont know how to embed the video but if you click it you can view it

https://farm8.staticflickr.com/7829/45827645475_e50f1eb741_n.jpg (https://flic.kr/p/2cPCEox)Turbo beetle (https://flic.kr/p/2cPCEox) by Dean Jones (https://www.flickr.com/photos/155782865@N06/), on Flickr

January 14th 2019, 17:04
231 hp at 18 psi with such a combo is a little disappointing tbh?
Or very very conservatively tuned?
There is surely room for improvement! ;-)

January 14th 2019, 18:02
I agree wally, something was amiss, I do wonder if I had valve issues before hand. I was hoping to make 230 sub 1 bar. Let’s hope the changes and new heads help out.

Steve C
January 16th 2019, 00:38

Nice work, I'm not sure how you have routed your lines on the intercooler but experts have told me to put the cooled liquid into the throttle body end of intercooler. I'm using a frozenboost.com reservoir which has a big mouth that you fill with ice to really get the intake temps down for drags etc. the reservoir is also good for getting air out of the system.


April 27th 2019, 05:19
It didn’t take long.....I killed it! I *think* it was mapped with a slight leak on the MAP sensor. The hose popped off and I pushed it all the way on. The ECU then kept reading overboost and IGN cutting. Kept dropping the duty cycle on the boost controller but I obviously spent too much time dropping small increments, over heated the heads and dropped a valve seat!

Anyway this gave me the opportunity to make a few changes. New heads (went a size smaller on inlet valves to leave more meat between the valves. Turns out my CR was super low and were now up at 8:1. I’ve also had the exhaust housing and turbine changed much smaller. Combine the upped CR and smaller exhaust housing I should see better numbers off boost and much faster spooling. All in all I’m hoping for much nicer driveability and similar numbers at lower boost. Going to the rolling road on Monday so we’ll see. Will map to 1 bar and see where we are at. Been looking into water/meth injection, anyone else running this? For relatively little cost it seems a good way to help limit heat which I guess is the big killer of boosted aircooled motors.

April 27th 2019, 05:35

April 27th 2019, 14:24

VERY nice car and stance!
Runs very smoothly as well. Pity about the troubles, but nice recovery!

Everything above 0,5bar boost or so (imho), you'd want some sort of intercooling. Water-meth is very efficient in doing so. I run Aquamist in the past and just received their newest version, but haven't installed it yet.

June 13th 2019, 13:06
Thanks Wally, itís taken me 10 years to get it just where I want it!!

Iíve got a charge cooler in place at the moment but long term I was looking at the AEM water meth kit. Itís fairly priced and seems like a good option to cool things down a bit!

I finally achieved my goal!!! 264hp at 16.5psi!!!!!
Makes 188hp at 11psi with boost controller off.

Figures havenít changed too much lower down despite the considerably smaller exhaust housing and increase in CR which is a little disappointing.. The weather has been aweful here so havenít had the opportunity to drive it since!

June 14th 2019, 15:45
Here’s a few runs whilst mapping. Max 264.5

Finally two runs, one with controller turned off (11psi) and one on (16.5psi)
HP boost


HP torque


June 15th 2019, 06:59
Figures havenít changed too much lower down despite the considerably smaller exhaust housing and increase in CR which is a little disappointing.. The weather has been aweful here so havenít had the opportunity to drive it since!

Thats a bit weird indeed. Pity your dyno didnt have the boost pressure in the graph.
It will probably feel very fast anyways 😉

June 15th 2019, 07:04
What engine combo is it now in this form?
Cam, ccís, heads/valves thanks!

June 15th 2019, 08:02
Hey Wally
The second link was boost vs hp (on my latest session) but not my previous session


It’s 2056, 38x42 with a web cam 118 turbo grind iirc

June 15th 2019, 09:03
Ah, so its 1 bar at about 4400-4500 rpm. Thats not too bad for basically a 2 ltr engine.
Maybe the compressor wheel is a big big for this hp? Compressor wheels determine spool almost as much as the exhaust wheel.
What turbo is on it atm?

This combo could/should do a little better as head size and cam seem ok for 300hp at 18 psi with these low inleg temps. Maybe timing has been kept a little conservative?

June 15th 2019, 14:58
I do think maybe the turbo isnít the best for my motor. Iíll drive it for a year or so and then maybe consider changing the turbo for something a little more modern. Iím running a Garrett t3/4 hybrid at the moment.

So at the moment it made max 264.9 at 16.5 psi, another couple of psi would be around the 300 mark I guess.

After the woes Iíve had with it over the last year I didnít want Greg (the chap mapping it) to push too far as I donít want to kill it again. I put 100 miles on it today mostly back at 11 psi and had loads of fun! Hat the boost controller on a few times and it was great.

In your experience Wally what sort of boost can you run to with stock head studs?

June 16th 2019, 17:15
Iíd say the head studs can handle way more then youíre now, but its the stock heads that trend to worp a bit, causing leaks.
Even stock engines saw this problem. Especially buses..
Anyways, never torque the head studs more then stock in an attempt to make it seal ďbetterĒ. It gets worse with more torque on the head studs then stock torque settings.
Thought Iíd mention that again, for others that might be tempted 😉

June 16th 2019, 17:38
Thanks for the heads up (pun intended 😂)
What tricks have you used to keep the heads sealed in the past, I understand your heads are far from stock now!

When I dropped a valve seat last time (18psi) we saw no evidence of the heads leaking which is good 👍

June 17th 2019, 07:45
Thanks for the heads up (pun intended ��)
What tricks have you used to keep the heads sealed in the past, I understand your heads are far from stock now!

Unfortunately none that can be used on cast iron liners.
Even then, I promised it was their intellectual ownership or s/th...

What helps are new heads (AMC seem a slightly better alloy) and keeping the bore stock, so preferably no machining that weakens the head. Good cooling and a really good tune are also just as important (and often overlooked/mistaken).
None of this is cheap though, I realize. But turbo is hp and there just is no cheap hp.