79 Convert Kaefer

[SuperRSi]

Well while waiting for parts for my Meyers Manx STi Pikes Peak car, I lost my storage building and had to pull out my 79 that had been resting for almost 10 years. So out came all the parts I have been collecting and I am getting her ready for new paint. Ordered Kerscher Kaefer cup flared fenders that arrive on United Airlines tonight and will be building a new rear apron. What a delight Kerscher is, one email, one Paypal and one week later fenders. It has KW-V2 coil-overs with MBT uniballs. Porsche GT3 seats, wheels, e-brake handle etc. My Mini-GT3...

http://i1119.photobucket.com/albums/k636/GreatFX/BugRearGT3Wheels_zps3049d695.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/BugRearGT3Wheels_zps3049d695.jpg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/BugDaylightShoes_zps9b5b9ee3.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/BugDaylightShoes_zps9b5b9ee3.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/GT3BugSide_zps2397760c.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/GT3BugSide_zps2397760c.jpeg.html)

[SportyBug]

Looks great and in far too few pieces for having been in storage.

Any chance you are in NM? Everything about that second picture looks familiar

[SuperRSi]

Yes in Santa Fe
And there are boxes and boxes of pieces in the shop upstairs.

[Humble]

I want to see more of this car as it comes together. I wanted to do a GL vert but I couldn't pass up a good deal when I saw one.

[SuperRSi]

I have a built Beetle 4 speed that will have a 2.3L Type IV attached about 180hp. The motor is being freshened at the moment. This will be a DD and street play car, maybe a little autocross. I will use Cayman S red brake calipers now that the Pikes car is getting yellow calipers. A leather/alcantera covered 911 style dash is now in the works using VDO 911 gauges and 904 combo gauge rebuilt about 10 years ago by North Hollywood Speedo. Audi TT A/C vents with full A/C. Webasto gasoline heater for winter. CAE shifter in aluminum.

In talks with Remmele now about providing the front bumper spoiler, CF hood and CF central air filter. Hoping that works.

[volkdent]

Any plans to stiffen the chassis?

Jason

[ricola]

Definitely sounds/looks like a great start!
Rich

[SuperRSi]

I plan to add DOM to the rear shock towers and torsion bar a la Remmele, and do the roll bar similar to the Canepa Twin Turbo Speedster that I think might be the best looking street convert 911 ever!


http://i1119.photobucket.com/albums/k636/GreatFX/CanepaTwinTurboRoll_zps3ab97e4d.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/CanepaTwinTurboRoll_zps3ab97e4d.jpg.html)
http://i1119.photobucket.com/albums/k636/GreatFX/CanepaTwinSide_zps8e725690.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/CanepaTwinSide_zps8e725690.jpg.html)

[Humble]

Canepa is local to me and those guys have all the fun. They open up their shop and parking lot once a month for cars & coffee. What I would give just to build a car in their shop, and some of their current projects have me drooling with envy. McLaren M8D, Shadow V8, and just about every kind of racing porsche you can find. He recently got the Tyrell P34 #4, and it's in race ready condition. Its also a lot smaller that I thought it would be, quite literally a 6-wheeled coffin. I can put up some pics if folks are interested.

[cookvw]

@ super RSI.....damn....im going to drive down to santa fe, nm as soon as i get my car dialed in. i wanna see your projects in the fleash. and im so close as well. look fwd to seeing this awesome car you got going here. keep it up man.

[volkdent]

That's going to look really subtle and the safety of the roll cage and side bars will be great. If it is all tied together it should significantly improve stiffness as well.

Jason

[70Turbobug]

Hey Randy, coming along nicely! If you're wanting to stiffen up the chassis,the best way is to support the shock towers.This keeps the rearfrom twisting and the shock towers are a weak spot.Take a look at my FB page,I posted pics of the conversion.You will have to cut the body a little,but that can be sealed up easy.

[cookvw]

@70turbobug im interested in this. whats your fb page?

[SuperRSi]

Hey Mark, I am tying in the roll bar back X to the towers and adding the lower bars in the rear like a 5 bar.

[70Turbobug]

That will work well also. I wasn't sure if you wanted a roll bar since it is convertable.

[SuperRSi]

I need the roll bar because sometimes I run out of talent...

[70Turbobug]

LOL! Yeah I know what you mean, I have ran out talent a few times myself!

[SuperRSi]

Fenders cleared Customs for a total of $31. in duty. Edi sent me an email on parts. Life is great. Pictures to follow.

[70Turbobug]

Great!! Good to hear! $31 for customs fee is great! Here it would be 23,5% of the total...

[SuperRSi]

Got a little time and test fit one rear fender. Things are going slowly because we are filming Longmire an A&E TV show and working 60-70 hours a week. Sleep a lot on weekends.

http://i1119.photobucket.com/albums/k636/GreatFX/RRearKerscherAbove_zpsadda11fb.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/RRearKerscherAbove_zpsadda11fb.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/RREarKerscherFrontSide_zps0b1ec094.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/RREarKerscherFrontSide_zps0b1ec094.jpeg.html)

There is no rear brake disc fitted so things will move out some and will use spacers as necessary.

This is a late aluminum 968 trailing arm with a Porsche OEM GT3 11 rear wheel inside an 11cm widened inside and out Kerscher fender.

[70Turbobug]

Looks good, nice fit!

[SportyBug]

Nice, it hides those huge rear tires well

[SuperRSi]

Spent some time fitting things before building the new seat brackets. Checking out the CAE shifter with the 993RS steering wheel and Rennline quick disconnect. Will build a mount and re cable the 944T rear to use the 996 GT3 handbrake. I am happy with the way things will fit.

http://i1119.photobucket.com/albums/k636/GreatFX/CAEshifter993RSside_zps7c7631ca.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/CAEshifter993RSside_zps7c7631ca.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/CAEshifter993RStop_zps91895961.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/CAEshifter993RStop_zps91895961.jpeg.html)

[SportyBug]

Strangely I think that the flare on those fenders stands out much more in photos than it does in person. In person the flare seems mild

[SuperRSi]

Orange against black does not help in photos...

[SuperRSi]

To continue this theme of everything I seem to buy to add to the bug is a shade of red/orange, I now add the door handles. These were purchased years ago from Carlotta (spelled wrong I'm sure) the guy that built the rising 911 rear wing on the back of a Bug. He was selling his Bug and I tried to buy the rear deck but he said all or nothing. Then he offered up these bolt on replacement door handles for the Super Beetle. So I bought them, and now a dozen years later have dug them out for use. My question is should I drill them like a light weight Porsche or leave them smooth? Opinions?

Smooth vs Original Chrome
http://i1119.photobucket.com/albums/k636/GreatFX/RedHandleCompare_zps7415afa3.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/RedHandleCompare_zps7415afa3.jpeg.html)

Yet another red/orange part
http://i1119.photobucket.com/albums/k636/GreatFX/redDoorHandleWide_zpsfa042b9f.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/redDoorHandleWide_zpsfa042b9f.jpeg.html)

[70Turbobug]

I would leave them smooth!

[volkdent]

Smooth fer sher.

Jason

[Kafer_Mike]

Smooth. What are the handles off of?

[SuperRSi]

Not sure but exact same mounting bolt and bottom end. 964 Porsche maybe? Will shoot a shot of the bottom next week when back.

[SuperRSi]

The guys in the shop gave me an opinion on waiting for parts and completion of my project. So nice of them to also pile parts inside...
I would ask if anyone wanted an original Kamei front spoiler but maybe I should wait for my Remmele one first.

http://i1119.photobucket.com/albums/k636/GreatFX/skeletonBug_zpsa560e0c2.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/skeletonBug_zpsa560e0c2.jpeg.html)

[Oval]

More info on those door handles please! What are they from?

Very inspiring project - I own a Cabrio and have a decision to make... restore or modify/GL it?

[SuperRSi]

Trying to get some work done before we go on to the next film. Working on brakes and suspension and could not help but plug two fenders on to see how they look. I think they will be fine once filled with tires. Have to remove A/C unit to remove gas tank. Always had gas smell from the POS so building an aluminum version to be bladdered and foamed. Will weld up fuel door and use a 911R through the hood fill on driver side. After that it is take out the dash board so I can start bending tubing for the roll bar system. Never ends...

http://i1119.photobucket.com/albums/k636/GreatFX/RearViewKersherFendersRED_zps542d8fb1.jpeg~origina l (http://s1119.photobucket.com/user/GreatFX/media/RearViewKersherFendersRED_zps542d8fb1.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/BugKersherFendersRED_zps8a920291.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/BugKersherFendersRED_zps8a920291.jpeg.html)

[SuperRSi]

Kafer Mike and Oval, I just saw the door handles on a Porsche 993. So that explains that.

Also working on spacers to fit the rear Falken 615K tires (315/30/18) and GT3 wheels tight into the Kerscher fenders. Working on suspension now and hoping to build a few tubular lower front control arms next week.

http://i1119.photobucket.com/albums/k636/GreatFX/BugRRearwSpacer_zpsac0f86fc.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/BugRRearwSpacer_zpsac0f86fc.jpeg.html)

[70Turbobug]

Sexy!! Keep it up Randy!

[Oval]

Hey thanks for the hint on the Porsche 993 handles

[SuperRSi]

They also may have been used on some 968s I am now told...

[Oval]

No worries.... it gives me something to ask for at the wreckers/breakers' yards

[petevw]

Looking good.

[al_kaholik]

968 handles are different to the 993 ones, but are a direct fit onto a beetle and early Golfs (Rabbit) The 993 uses a two stud fitting rather than the hook that you find on the beetle.

993 do look the better of the two but neither are cheap nor plentiful

[SuperRSi]

Finished re doing my old 2.3L Type IV with the FAT 911 cooling and BAS Stainless Cup Exhaust. About 175hp. This will do until I can afford to build a Nickie engine with Klaus cooling I bought parts for from Alex N. here. And hopefully a set of Thorsten Pieper billet heads in 102mm.

http://i1119.photobucket.com/albums/k636/GreatFX/T4BASWide_zps9fb8e1b6.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/T4BASWide_zps9fb8e1b6.jpeg.html)

[volkdent]

Do you have an ETA for getting this thing on the road?

Jason

[SuperRSi]

Depends upon how long it takes the paint shop. They promise 4 weeks. The last company that told me 4 weeks delivered in 19 months. So when it gets back, new wiring, install 911 dash, interior seats carpet, all new rubber seals, new top. Trying for summer here which is by Oct at latest. We shall see...

[SuperRSi]

I have decided to build the engine using the parts I bought from Alex N. Here about 10 years ago. I am buying 70turboBug's heads and building up an 86X102 2.8L.

My 2.3L engine shown here is for sale at $5,000. In Santa Fe New Mexico. The BAS Cup exhaust is not included and will be used on the new engine.

[70Turbobug]

Sounds like a plan Randy! Have you made cam choice yet?

[SuperRSi]

What do you recommend?

[70Turbobug]

I would go with a Schleicher 332 or Nowak 332° cam,depending on what compression ratio you are planning. With those 2 cams I would go with an 11:1 CR. If you are planning or have to go with a lower CR i.e. 9,5-10:1 A Schleicher 324° would be a good choice. All these cams are not "lumpy" like the Webcam 86c or bigger. Both Schleicher and Nowak have a smooth idle and are well mannered until you hit the throttle. The 332° cams have a 10.26mm cam lift.

[SuperRSi]

I have had to put the engine build on hold until I sell my old engine. In the mean time I have been working on seat mounts for the factory GT3 seats. Tubes are 1.5 inch .120 DOM steel.
http://i1119.photobucket.com/albums/k636/GreatFX/imagejpg1_zps2121b507.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/imagejpg1_zps2121b507.jpg.html)
http://i1119.photobucket.com/albums/k636/GreatFX/imagejpg2_zpsb48295c3.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/imagejpg2_zpsb48295c3.jpg.html)
http://i1119.photobucket.com/albums/k636/GreatFX/imagejpg3_zpsd4a7a27a.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/imagejpg3_zpsd4a7a27a.jpg.html)

[70Turbobug]

Looking good,Randy! Maybe I can give you a call this week?

[ricola]

Looks good but the body won't be coming off the chassis again any time soon!

[SuperRSi]

Nope no more body off anymore, even less the roll bar, door bars and such are tied in. Mark call me. We work days slowly shifting to night as the week progresses. Usually 15 on 9 off.

[SuperRSi]

Looks good but the body won't be coming off the chassis again any time soon!

Sawzall will make short work of tubing if necessary. But roll cage will be the bigger worry.

I have scrapped my STi powered race Manx for Pikes Peak and am now putting that 400hp+ engine in the bug with a Subaru RA Trans. More to come after I recover from knee surgery.

[70Turbobug]

I think that is a good choice Randy! You have a finished engine ready to install and it has more power and reliability. Didn´t you have a 930 trans also?

[SuperRSi]

Hey Mark, I do have the 930 Trans but the Suby 5 speed is easier and I need to get it on the road and out of my shop!

[70Turbobug]

If you're interested in selling the 930 trans,let me know.

[SuperRSi]

I have the 930 and new center force clutch. I should sell them to buy a certain Pikes Peak car I am looking at buying...

[SuperRSi]

Now working on finishing the Manx and putting the Type IV on this thread in it. After I get the Manx running and out of the shop, I will then jump back on to the Beetle. The nice thing is I have figured out the STi/930 transmission will fit without cutting the torsion tube. Trying to do the easier first. Anyone want a Manx/Mendeola suspension/T4 buggy thread on the build here?

[SuperRSi]

Traded the 996GT3 wheels for these perfect BBS RS-GT wheels. A little more period correct for the overall look I am going for with my Mini RSR Turbo.

http://i1119.photobucket.com/albums/k636/GreatFX/IMG_0373_zps43eb6c19.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/IMG_0373_zps43eb6c19.jpg.html)

[70Turbobug]

Well hell yeah Randy, post all of the projects on here!

[SuperRSi]

This is the engine and trans I am about to stuff into the back of the Beetle. It was being built for Pikes Peak in a Manx so it will stick out of the back of the Beetle. Should make an interesting ride. And yes I am trying to fit an air-conditioning compressor, alternator and a dry sump pump on there.

http://i1119.photobucket.com/albums/k636/GreatFX/IMG_0313_zpsc0b03261.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/IMG_0313_zpsc0b03261.jpg.html)

[SuperRSi]

This is the Porsche version of what I will end up with. My build of headers to turbo to intercooler to intake is based on this design.

http://i1119.photobucket.com/albums/k636/GreatFX/RSRTurboEngine_zps5027a5e1.jpg~original (http://s1119.photobucket.com/user/GreatFX/media/RSRTurboEngine_zps5027a5e1.jpg.html)

[70Turbobug]

That would be the ideal solution, but that´s going to be a tight fit under the apron and to be honest,I don´t believe there will be enough room. That´s basically the same idea I had,but after measuring and comparing on another bug in my shop....there´s no way to do it and keep it under the apron and decklid. You may have to relocate your intercooler from it´s present position also if it is going to fit under the decklid. The cam wheel cover on the DOHC suby takes up quite bit and makes it longer than a type 4. You could move the trans/motor package forward a couple of inches requiring you to cut the torsion tube and the frame horn. Even then it will be real tight.

Mark

[SuperRSi]

Apron and deck Lid? I don't need no apron and the deck lid will be short like the RSR. I am thinking of making it Matt black with Martini stripes. Widow maker paint job, maybe appropriate when the boost is up...

For sure the engine exhaust and turbo placement rule out an apron. Just like the RSR lost the center of the bumper and it didn't have a muffler to put ther either.

[70Turbobug]

Ah ok,didn´t know what your plan was ;) There was Porsche 918 during it´s developement stages that had a matt black paint job with the Martini stripes and logos...looked pretty bad ass!

[SuperRSi]

Well the longer it takes the more changes happen. I have received some Remmele parts for my Billet engine so at the request of the spousal unit to keep the convert a street car, the 2.8L Billet is going in. Here are a few photos of the Billet Remmele Motorsport heads with the LN Engineering Nickies I purchased here almost 10 years ago...

http://i1119.photobucket.com/albums/k636/GreatFX/image_zps2k13ylhc.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/image_zps2k13ylhc.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/image_zps4hbw7ovt.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/image_zps4hbw7ovt.jpeg.html)

[SuperRSi]

come closer...

http://i1119.photobucket.com/albums/k636/GreatFX/image_zpsgqsht9im.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/image_zpsgqsht9im.jpeg.html)

[SuperRSi]

More Remmele parts are on the way and will be posted as they arrive. None of this would have been possible without the help of 70TurboBug Mark. Thanks to Mark for being the intermediary on all the ordering, taking delivery of the parts in Germany and then shipping them to me in New Mexico. The plans for the engine are 102 Nickie cylinders, JE FSR billet pistons, and 80mm SCAT billet crankshaft. I am talking with Pauter about some rods. The build will be slow as it absorbs lots of money and then has to wait while I earn more! I am hoping to get an early G50 transmission and cram it into the chassis. More to come...

[Wally]

Nice! Great parts collection!
BTW there's an early G50 for sale from a vw guy over here for a bid over 2000 euro iirc.

[SuperRSi]

I have a hook on a RS America transmission with 40,000 miles, but we are working on the price. He wants $4,000. And I don't...

[70Turbobug]

What´s up the 930 trans? Wally´s suggestion is an excellent price. Currently, early G50´s are running between 3500-5500 Euros used and not overhauled. For that price,I would rather spend an extra 1k and get a new Mendeola and have a shorter shift pattern also. I love G50´s but there are those evil parts trolls that buy up the market and jack the prices up. It´s not really worth it anymore. Going with the suby trans conversion will cost just as much and the suby 5 speed is much weaker, I don´t care what others say,they are no where near as strong as a G50 or Mendeola and are much weaker than the 6 speed suby trans,also. For my turbo project, I will eventually go with a Rhino case and all Weddle gears or Kuplapaya from Finnland.That should do for my use just fine. As of now I have a Rancho pro-street plus,which probably will not last long..

[SuperRSi]

I am continuing this build slowly but surely again now with the subi and a 2007 GT3 transmission I just bought. The build is on Facebook as Psycho Beetle.

[cookvw]

post up a link.

[effvee]

Well the longer it takes the more changes happen. I have received some Remmele parts for my Billet engine so at the request of the spousal unit to keep the convert a street car, the 2.8L Billet is going in. Here are a few photos of the Billet Remmele Motorsport heads with the LN Engineering Nickies I purchased here almost 10 years ago...

http://i1119.photobucket.com/albums/k636/GreatFX/image_zps2k13ylhc.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/image_zps2k13ylhc.jpeg.html)

http://i1119.photobucket.com/albums/k636/GreatFX/image_zps4hbw7ovt.jpeg~original (http://s1119.photobucket.com/user/GreatFX/media/image_zps4hbw7ovt.jpeg.html)

Hey, why isn't the site administrator banning this type of eye candy:lmao:

[SuperRSi]

The sad thing is all those parts have been sitting waiting for other Remmele parts. Maybe soon. That engine will go in my Manx. The Bug build can be seen on Facebook as Psycho Beetle. Working on it again this month. Been working too much to get much of anything done.

[rioprelude]

Looks like the Facebook link is here: https://m.facebook.com/PSYCHO-BEETLE-278172909189251/

[SuperRSi]

Slowly moving ahead as money allows,

[effvee]

It looks like you are into MAD SCIENCE :eek:. Nice work, nice taste.

[CoolT1]

How much did the Kerscher fenders cost landed and how wide did you go ?

[H2OSB]

not gonna lie...I love that rear end treatment. I flat T4 would look sparkly sticking out the back end of that.