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Xellex
September 25th 2008, 05:18
Hi guys, I finally feel confident enough to start up a project thread for my bug here, on the GL forums. It's a late start, but I wanted to learn stuff better before I apply it, and I have to thank you all for that.
The germanlook style fit my dreams and my ideas like a glove, an I've dreamt of a bug that I'd work on, ever since I was a child.
I only got one last year, at the age of 25, but I'm a VW forum lurker ever since I can remember having a computer, and I'm happy that I've waited until now, mostly because the bug I bought was in such a good shape, and also, that now I mostly know what to do to it.
I'll be posting pictures here, progress and thoughts.
In the meantime, here's my bug, as it looked like last year in may, when I bought it.
It's a '73 1303S ('74 model with 2 bolt struts), and I knew about it for 1 year before I finally got it.

Xellex
September 26th 2008, 20:25
Ok the main reason why I wanted a bug in such a good shape was that I wanted to drive it and enjoy it eaven before I'd start working on it. And that's what I did!
Last year I've been all around the country with my bug, and it's been great! Nothing broke down, and it ran awesome. With a few exceptions: at some point the carb got some dirt in it and I decided to do a carb overhaul, so I bought a kit, and did it myself. After that the speedometer cable tip got worn (the square part rounded up) and I exchanged it.
Oh, and the verry first job I did on the bug was to clean and paint the rims, and to install the chrome hubcaps, because the previous owner had some ugly hubcaps on it.
That's what it looked like before I got it:

Wally
September 27th 2008, 15:36
It looks clean and nice! The '74 with the 'Golf' struts is a good year for a GL to start with ;)

Xellex
September 27th 2008, 19:05
Thanks, it's as close as I could get to the car I had in mind. My prefferate car out of all the bugs is the '75 with the r&p steering. but then again, the r&p conversion can be made into a nice project
To continue the story, before I bought my bug, I had no technical experience whatsoever, and almost everything I knew about beetles was from the internet. That's why I wanted to take it slow, and that's why the first steps I took towards the GL were a few easy ones:
First of all I took off those ugly "sport" mirrors and installed the original chrome one. If it's not GL than let it be stock :P
And then I got 2 smoked taillights.
http://img521.imageshack.us/img521/4496/dsc02165hb2.th.jpg (http://img521.imageshack.us/my.php?image=dsc02165hb2.jpg)http://img403.imageshack.us/img403/5766/dsc02166ti8.th.jpg (http://img403.imageshack.us/my.php?image=dsc02166ti8.jpg)http://img521.imageshack.us/img521/4886/dsc02174oa7.th.jpg (http://img521.imageshack.us/my.php?image=dsc02174oa7.jpg)http://img403.imageshack.us/img403/6941/dsc02177nt4.th.jpg (http://img403.imageshack.us/my.php?image=dsc02177nt4.jpg)http://img403.imageshack.us/img403/6725/dsc02207ha2.th.jpg (http://img403.imageshack.us/my.php?image=dsc02207ha2.jpg)


Then I bought "clear 3 chamber" headlights, with turn signals incorporated in them. I didnt relocate the turn signals yet because it would look strange still haveing the ones on the fenders too.
http://img88.imageshack.us/img88/5909/dsc02187gr2.th.jpg (http://img88.imageshack.us/my.php?image=dsc02187gr2.jpg)http://img88.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img88.imageshack.us/img88/3397/dsc02192hv3.th.jpg (http://img88.imageshack.us/my.php?image=dsc02192hv3.jpg)http://img527.imageshack.us/img527/1669/dsc02193ej7.th.jpg (http://img527.imageshack.us/my.php?image=dsc02193ej7.jpg)http://img517.imageshack.us/img517/2870/dsc02195ge3.th.jpg (http://img517.imageshack.us/my.php?image=dsc02195ge3.jpg)

Xellex
October 4th 2008, 17:53
When I installed the new headlights I realised the high and low beam were inversed, so when I turned on the headlights they were already on hi, and when I was using the high beam. you couldnt see much difference.
After I fixed it, I was a bit dissapointed about the quality of light. The fact that I already had a plan, maybe contributed to that :P
So I bought a HID conversion kit. It's not a bi-xenon. Only the low beam is HID, and the high beam is halogen, but it's ok. I don't disturb the incoming traffic at all, and the light is awesome.
You can see one HID and one old halogen headlight in the last pic.
http://img383.imageshack.us/img383/5474/dsc02215ap2.th.jpg (http://img383.imageshack.us/my.php?image=dsc02215ap2.jpg)http://img383.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img376.imageshack.us/img376/5939/dsc02216or5.th.jpg (http://img376.imageshack.us/my.php?image=dsc02216or5.jpg)http://img376.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img376.imageshack.us/img376/6307/dsc02219wf7.th.jpg (http://img376.imageshack.us/my.php?image=dsc02219wf7.jpg)http://img376.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img204.imageshack.us/img204/3946/dsc02221ad0.th.jpg (http://img204.imageshack.us/my.php?image=dsc02221ad0.jpg)http://img204.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img231.imageshack.us/img231/237/dsc02222mh0.th.jpg (http://img231.imageshack.us/my.php?image=dsc02222mh0.jpg)http://img231.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)

volkdent
October 4th 2008, 21:06
Wow, quite a difference in light output!!! So Halogen low, HID high? Where did you get that from?

Jason

Xellex
October 5th 2008, 07:12
no, all the way around: HID low(the one that you commonly use), and halogen High.
I only bought it like this because it was cheaper and easier to come around last year. Nowadays things have changed and you can buy a bi-xenon kit for a fair price.
I got mine from a friend's tuning shop, but I'm sure you can easily find a kit on ebay or a parts store. ;)

A few pics with the car after the snow melted away last spring:
http://img524.imageshack.us/img524/5474/dscf2180hv9.th.jpg (http://img524.imageshack.us/my.php?image=dscf2180hv9.jpg)http://img524.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)http://img524.imageshack.us/img524/1219/dscf2188cd7.th.jpg (http://img524.imageshack.us/my.php?image=dscf2188cd7.jpg)http://img524.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)

Xellex
October 9th 2008, 19:03
As spring came I started driving my bug more and more, but something felt wrong so I sent my carb to have it reconditioned and the guy did and awesome job.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-02-08%20Carb%20reconditionat/th_DSCF2195.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-02-08%20Carb%20reconditionat/DSCF2195.jpg)
After that I had to take our equivalent of the MOT so I had to do a complete brake system overhaul. That was my biggest job on the bug at that time.
Then I found an ad about a couple of type4 engines, so I went and bought a 2000cc CJ engine.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-03-24%20Motorul%20tip4/th_25032008001.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-03-24%20Motorul%20tip4/25032008001.jpg)
After that I started gathering parts to do a Cali conversion, thinking I wont have enough money to get a porsche style cooling system. But I put that project on hold for a while.

In may, me and my girlfriend went to Hannover at the Maikaefertreffen, as my birthday present. I can't describe how nice that was.
I didnt have too much money to spend for parts in Germany, but I had to get something for my bug, so I got an antenna because mine was broken, and also a "Quick-shift kit" that I installed and it's great.
You can see all the pics I took HERE (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-05-01%20Hanovra%20si%20Wolfsburg/)
Shortly after we came back, there was a beetle meeting in my country, in the city of Timisoara, so we went there too. It was great fun.
Pics HERE (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-05-26%20Intalnire%20Timisoara/)
I found something that I wanted for a long time at that meeting: a pair of Opel Manta side mirrors.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-05-30%20Oglinzi%20de%20manta/th_DSCF2003.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-05-30%20Oglinzi%20de%20manta/DSCF2003.jpg)
And that was one of the last times I drove my bug, because something pretty nice happened...

Xellex
October 9th 2008, 19:20
... I managed to find a Porsche enthusiast that had a donor 1989 Porsche 944, and the only thing he wanted to use from that car was the dashboard and interior parts.
At first I only went there and got the seats. They need new upholstery but they are ok.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-06-20%20Scaune%20de%20Porsche%20944/th_DSCF2009.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-06-20%20Scaune%20de%20Porsche%20944/DSCF2009.jpg)
But then I started thinking: dude! how often do you find a Porsche 944 in Romania to get the parts you want from it? So I took a trip to that guy again and bought everything I thought I would use.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-06-30%20Puntile%20de%20944/th_DSCF2001.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-06-30%20Puntile%20de%20944/DSCF2001.jpg)
And that's where the real work started on my bug. I work alone, I don't have a garage, and I dont't have any mechanical experience, so things go very slowly. But I'm happy with how things are going, and I'm enjoying every second I'm working on my bug.
I have to thank everyone that contributed to these forums, everything I do on my bug is inspired from the web, mostly from here.
I'm trying to take alot of photos, to give something back to the comunity. All my albums can be found at this link:

PRESS HERE FOR ALL MY ALBUMS (http://s260.photobucket.com/albums/ii25/xellex_anonim/)

I know the titles are in romanian, but everything is laid up in a chronological order, so it's gonna be extremely easy to go through.

I hope you guys will enjoy the pics, and I'm very open to suggestions, discussions, ideas, any kind of chat and feed-back.

Xellex
October 9th 2008, 19:40
And this is where I am at the moment:
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-11%20Cauciucuri%20spate/th_DSCF2004.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-11%20Cauciucuri%20spate/DSCF2004.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-11%20Cauciucuri%20spate/th_DSCF2009.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-11%20Cauciucuri%20spate/DSCF2009.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-10-06%20Kit-ul%20de%20bucsi%20din%20urethan/th_DSCF2117.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-10-06%20Kit-ul%20de%20bucsi%20din%20urethan/DSCF2117.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-26%20ultima%20janta%20si%20alte%20piese%20vopsite/th_DSCF2013.jpg~original (http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-09-26%20ultima%20janta%20si%20alte%20piese%20vopsite/DSCF2013.jpg)


I cleaned, inspected, painted and mounted every porsche part onto position, including the wheels. It's easier this way, because seeing it take shape motivates me, and it's also makes me realise exactly what else I need next.
The back end is almost done, as I found drive axles too, I've installed the urethane bushings, the bump-stops. All I need and I'm waiting for is the hand-brake adaptors. And the porsche sway-bar mounting kit.
In the front things are more complicated, as I need to get custom struts. I ordered the kerscher ball-joints. Now I'm cleaning the sway-bar and the a-arms and installing the urethane bushings.

Xellex
November 6th 2008, 17:27
Ok the handbrake is perfectly working again, thanks to the Vdub engineering conversion parts, thanks Lanner!

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-10-25%20Am%20terminat%20frana%20de%20mana/th_DSCF0026.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-10-25%20Am%20terminat%20frana%20de%20mana/?action=view&current=DSCF0026.jpg)

I pulled the old master cylinder out of the car. It turned out it wasnt the correct 1303 MC, it was a dual circuit old style beetle MC, altho this wasnt a problem.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/th_DSCF0041.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/?action=view&current=DSCF0041.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/th_DSCF0043.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/?action=view&current=DSCF0043.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/th_DSCF0049.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-04%20Pompa%20de%20frana%20de%20Porsche/?action=view&current=DSCF0049.jpg)

Now I'm in the process of adapting the 944 MC to the bug. I know everything I have to do, thanks to all the info you guys posted about this on the forums.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/th_DSCF0056.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/?action=view&current=DSCF0056.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/th_DSCF0057.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/?action=view&current=DSCF0057.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/th_DSCF0059.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/?action=view&current=DSCF0059.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/th_DSCF0060.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/?action=view&current=DSCF0060.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/th_DSCF0067.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-06%20Adaptari%20Adaptari/?action=view&current=DSCF0067.jpg)

Still, there is something that's not clear. I've read all the opinions, arguing, debates etc :P about the 944 MC and the brake bias, but I'm still not sure if it's a good idea to reverse the pipes to the MC, front pipe to rear piston, and rear pipe to front piston. It would be much easier bolting them on like that, and not doing some extra plumbing but I have to know for sure it's a good thing to do...

evilC
November 7th 2008, 10:08
The front pipes must go to the rear piston i.e. the one closest to the pedal and the rear brake line to the front piston. The reason for this is that the rear piston has only a hydaulic connection with the front piston so that when you press the pedal the rear piston pressurises its circuit and then pressurises the front piston. Usually the front brake pistons are larger than the rear so that the front brake m/c piston needs to move further potentially that the rear piston. If you plumbed it the otherway round the rear brake would hydraulically lock everything up before the front got to anywhere near its full travel.

evilC

Xellex
November 7th 2008, 11:30
yes, that's what I thought. Still, there are a few people on this forums that plumbed it the other way around. I think Wally did it too. Am I right?

Wally
November 7th 2008, 17:02
Yeah, but I plumbed it back and actually removed the 944 MC all together and used a bug 19/19 MC again ;)
My thinking is that larger diameter MC brakes with less force and if you don't realy need the lesser pedal travel, you better use the smallest piston for the most pressure inside the MC. More pressure= lesser brakepedal effort= harder braking.

Xellex
November 7th 2008, 19:37
I think that would only be true if the calipers were the same size front/rear, and if the 19mm would push enough fluid to succesfully move the big NA 944 front caliper pistons.
Your thinking makes perfect sense, but imho the total volume of the pistons inside the calipers at full braking (expanded the most / brakes locked) has to be equal or lower to the volume of the piston inside the MC when pedal is released. If it's bigger then there's a big problem.
So yes, the lowest volume MC piston is the best, but there's a lower limit, and there's also a higher limit, to the point where brake effort is too high, and pedal travel is extremely small.
The question is: does the 19mm MC fit somewhere above that lower limit? Ofcourse on the street/track you could get great results, and good braking because the bug is so light.
And the second question is: what does that do to the rear, lower volume calipers? Probably locking them too early.

That's just my late night thinking, and the only fluid dynamics classes I took were in college, so I could be very wrong.

Anyway I'll just do the extra plumbing and mount the MC the normal way.
Thank you for your response, I apreciate it.

flat
November 8th 2008, 20:29
I've tried to stock 19mm dual circuit MC with 944NA brakes, and it doesn't work well. Not enough volume. You need the 944MC for the NA brakes. With aluminum brembo's, the stock 19mm works extremely well.

Lanner

evilC
November 10th 2008, 08:47
The original standard m/c for the 944 was a 19/19 unit that was later changed to 23/19 and that is the one that most people refer to as the 944 m/c. Fluid volume is not really the issue with a fully working system with good lines and fresh fluid (well bled). The basics of hydraulic advantage is that the pedal effort is multiplied by the area of caliper pistons (2No.) / area of mc piston. The stand off of the pad from the disc is very small so as minimise pedal travel. The main effects on pedal travel are hose bulge and water/air in the system that then compresses.
On a bug with a larger caliper piston area at the front than on the rear the stepped m/c can be of some advantage as the desireable brake bias is unity i.e. the braking effort front and rear should be about the same. The larger m/c piston is around 45% larger in area than the smaller piston and therefore gives 2/3rds the fluid pressure than the rear line.

evilC

Wally
November 10th 2008, 09:06
Yeah, that too :D

flat
November 10th 2008, 09:47
I've just speaking from my experience. The 19mm stocker didn't feel right with the 944NA brakes, the pedal travel was too deep. Everything on the car was new/rebuilt, with fresh fluid in the system. It would brake, but you felt the need to pump the pedal to get the required volume. Swapped it over for a 23/19 MC and it was amazing. Tall pedal + great clamping = driver confidence. The 19mm MC worked, but the 23/19 worked MUCH better.

So, the question boils down to this: Has anyone used a 19mm stock MC on a 944 NA brake system with good success?

Lanner

Simon
November 10th 2008, 10:45
Nice looking car!
Like your kind of diary style writing btw :)

Then I bought "clear 3 chamber" headlights, with turn signals incorporated in them. I didnt relocate the turn signals yet because it would look strange still haveing the ones on the fenders too.
Are those these plastic ones http://www2.cip1.com/ProductDetails.asp?ProductCode=ACC%2DC10%2D7580 ?

If so, how does the light coming through the lens look?
I'm looking for a clean way to integrate my turn signals into my headlights, but I heard the light quality coming out of these isn't all that good.

evilC
November 10th 2008, 11:58
I've just speaking from my experience. The 19mm stocker didn't feel right with the 944NA brakes, the pedal travel was too deep. Everything on the car was new/rebuilt, with fresh fluid in the system. It would brake, but you felt the need to pump the pedal to get the required volume. Swapped it over for a 23/19 MC and it was amazing. Tall pedal + great clamping = driver confidence. The 19mm MC worked, but the 23/19 worked MUCH better.

So, the question boils down to this: Has anyone used a 19mm stock MC on a 944 NA brake system with good success?

Lanner

I have left the standard 19/19 dual circuit m/c in my build up with turbo 4 pot calipers on the rear and for now the 944 N/A single pots on the front. All of this is with new hard lines and ss teflon hoses together with a bias valve in the rear line as I expect/want a rear bias that I can dial out at will. I have yet to fill the system so can't report on pedal feel but all my calcs lend themselves to a solid pedal. I also have a stepped 944 m/c should I need it but that would make the bias even more to the rear and was only anticipating using it with the 4 pot turbo calipers that I was looking to use should an upgrade be required.

What rear calipers are you running?

Nice looking car!
Like your kind of diary style writing btw :)


Are those these plastic ones http://www2.cip1.com/ProductDetails.asp?ProductCode=ACC%2DC10%2D7580 ?

If so, how does the light coming through the lens look?
I'm looking for a clean way to integrate my turn signals into my headlights, but I heard the light quality coming out of these isn't all that good.

I've got a pair of similar ones with a clear lens to go onto the '03 (Super). If those are anything like mine then they are Golf MK1 (Rabbit) and require new fitting tabs for the headlamp bowl. Also, I haven't yet worked out a quick way to change blown bulbs without completely dismantling the lamp, which of a foul weather night will be a serious pain especially on a competitive road rally. I wouldn't consider indicators within the lamp as over here several manufacturers have gone down that route for styling reasons only to make them difficult to see when the headlamps are on. There was some discussion over here about using the sidelight bulb in yellow as the indicator but that is even worse IMO as it will be only a 5 watt unit instead of the 21 watt required by law.

evilC

flat
November 10th 2008, 12:46
Sorry to jack the thread, but just to share my experience. I've tried a few setups with different masters:

944NA with 19mm stock dual circuit- pedal too low, but works

944NA with 23/19, very nice, tall pedal, good actuation.

944T with 23/19, pretty good, but hard pedal, amazing actuation.

944T with 19mm dual, about perfect.

986S with 19mm dual, amazing. easy pedal and will pop your eyeballs out of the socket.

964 C2 with 23/19, good, but could be better. Probably 20mm dual circuit from a 911 would be best.

I've never tried mixing NA and T components on the same vehicle, so I don't have any feedback to share. All the above setups were tested on a 1302 beetle or split window bus.

Lanner


What rear calipers are you running?
evilC

ricola
November 10th 2008, 13:44
stock 944 NA front brakes and standard 19mm m/c I found I didn't get enough travel (pedal was bottoming out), maybe if they were all fully bedded in they would get borderline acceptable?

Xellex
November 10th 2008, 14:25
thanks for all the input guys, I really apreciate it.

@ $aint: thank you, I really hope I can bring something back to this great comunity.
About the headlights, yes they are the same as those on Cip1, but mine have clar glass all the way. So the light output is awesome.. much better than a new car, but not disturbing the incoming traffic.
They are made all out of plastic and the overall quality is not that good, but acceptable for now.
There is that problem about having to remove them if a light bulb gets blown, but Xenon headlights should hold much much longer than halogen ones. (at least in theory).
About incorporating the turn signal bulbs in them, I wanted to do it too, but now I think it's not a very good idea. The radius from where they can be seen would be too small. Instead of that, I want to incorporate fog/city lights in them, and place the turn signals in the bumper.

yellow73
November 15th 2008, 21:35
You have a really clean car. I am enjoying your reading about your progress.

Xellex
November 16th 2008, 07:04
thank you, I'm happy to hear that :)
I made some more progress last week. I decided to make the custom brackets for the rear Porsche stabilizer bar, and I copied the Kerscher design. They didn't come out as nice as the german ones, but they worked ok.
The lower part, where the bushing stays is actually the original piece that I removed from the Porsche torsion bar housing.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/th_DSCF0054.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/?action=view&current=DSCF0054.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/th_DSCF0058.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/?action=view&current=DSCF0058.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/th_DSCF0063.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/?action=view&current=DSCF0063.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/th_DSCF0072.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-08%20Bara%20stabilizatoare%20spate/?action=view&current=DSCF0072.jpg)

I assembled the Porsche drive axles, with Beetle CV joints to one side and Porsche CV joints to the other.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-13%20Remontat%20Planetarele/th_DSCF0006.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-13%20Remontat%20Planetarele/?action=view&current=DSCF0006.jpg)

Xellex
November 16th 2008, 07:12
And the Kerscher ball-joints came with the mail, so I went to a shop to replace the original ones. I also drilled the hole in the spindle, for the speedometer cable. It came out very nice. And I installed the urethane bushings into the A-arms.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-13%20Remontat%20Planetarele/th_DSCF0080.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-13%20Remontat%20Planetarele/?action=view&current=DSCF0080.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF0095.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF0095.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF0104.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF0104.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF2493.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF2493.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF0085.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF0085.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF0089.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF0089.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/th_DSCF0103.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-15%20Gaura%20in%20fuzeta%20pt%20vitezometru/?action=view&current=DSCF0103.jpg)

Xellex
November 19th 2008, 21:29
This goes to Wally and the other guys living in the Netherlands: I just got tickets and I'm gonna spend Christmas (23Dec-27Dec) with my girlfriend and brother in Hague and Amsterdam.
I've checked the keversite website, but I can't understand much of it. (other than the fact that there's alot of activity in the netherland's aircooled world) I want to know if there's something bug/aircooled related that's worth visiting in that area.
The Paruzzi store seems close... maybe it's worth going there. Anything else interesting? (kieft&klok maybe?)
Oh, and I'd love to meet you and see the white bug and the 411.
Thanks ;)

Xellex
December 5th 2008, 22:35
Haven't done much to the bug lately... Master brake cylinder is in now, so are the drive axles. I had to shorten that pedal push rod that goes into the MBC about 1cm.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-18%20Pompa%20de%20frana%20si%20planetarele%20monta te/th_DSCF0014.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-18%20Pompa%20de%20frana%20si%20planetarele%20monta te/?action=view&current=DSCF0014.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-18%20Pompa%20de%20frana%20si%20planetarele%20monta te/th_DSCF0022.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-18%20Pompa%20de%20frana%20si%20planetarele%20monta te/?action=view&current=DSCF0022.jpg)
And I changed the gear coupler bushings. I'm extremely happy with the results, but I will have to change that bushing in the tunnel too, to get everything perfect.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-19%20Cuplajul%20de%20la%20cutie/th_DSCF0028.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-19%20Cuplajul%20de%20la%20cutie/?action=view&current=DSCF0028.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-19%20Cuplajul%20de%20la%20cutie/th_DSCF0032.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-19%20Cuplajul%20de%20la%20cutie/?action=view&current=DSCF0032.jpg)
I will have to order the custom struts soon, but it's not on my priority list with christmas/new year and all.
I've ordered a full braking hard lines kit, after I tried to re-route one of them and it broke in my hand.
Oh, and I cleaned the Porsche R&P steering, to be able to handle it without getting my hands dirty. It's a challenge but I really want to try and make it work... we'll see if I'm gonna get anything good of it. If not, then I'll probably settle for a stock post '75 1303 R&P.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/th_DSCF0043.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/?action=view&current=DSCF0043.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/th_DSCF0044.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/?action=view&current=DSCF0044.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/th_DSCF0045.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2008-11-21%20Curatat%20caseta%20directie/?action=view&current=DSCF0045.jpg)

Still waiting for a response to my previous post, if any1 in knows anything and is willing to share :p

evilC
December 8th 2008, 06:47
Xellex, are you convinced about using the porsche rack? i have a couple of queries:
1) The porsche rack looks as though it will give a huge amount of bump steer as the pivot point is too far outboard for the pivot point of the lower suspension arm.
2) I would have thought that utilising a power steering unit will be overkill for such a light front end and you will lose all feel.

A standard steering rack would be the way to go and it should be quick enough for most circumstances.

evilC

Xellex
December 8th 2008, 22:38
well I'm not 100% convinced, but if I have it, why not give it a try... If the results are not gonna be ok, then I switch back to the stock steering and try to source a late 1303 rack.
Yes, I've read about the bump-steer problem alot all over the aircooled forums, but I've never actually heard it/read it from someone who has really done it.
The pivot point is actually not that far out, compared to the stock 1303 pivot point (not r&p version). I'm gonna get exact measurements, and yes, I realise only a few mm could matter for a good or bad setup.
Right now, it looks like everybody is saying "don't do it, yo're gonna get bump-steer!" based on calculations, maybe engineering studies or experience, or just a hunch (did I spell that right?) ....At least I'm gonna be the one to say "Don't do it, I've already tried that and it sucks!" :p
There's a subaru powered bug featured in the 2008 Kaefer Revue Magazine that has this conversion, and it looks like it's working.
And yes, mine is the power steering unit, but w/o a pump, it should be just like the normal one. I'm not planning on using a pump for the start at least.
I've read everything I could find on steering setups and the bump-steer effect, but it's not much. If you guys can point me to some more info, I would be grateful.
I'll take into consideration everything you guys might have to add, pros or cons. The first thing for me too is safety.. That's for sure!
The only other porsche rack setup, I found, besides the one in that magazine would be in these 2 pictures, but I can't remember where they are from:

Xellex
December 8th 2008, 23:12
I could be very wrong, but I think bump-steer has more to do with the position of the rack (height, forward/rearward pos. and perfect paralelism to the ground axis) than it has to do with the length of the tie-rods, compared to the length of the a-arms. Of course, as long as the tie-rods are the same length left-to-right, not like the older beetle steering systems.

evilC
December 9th 2008, 10:42
Your first photo is an excellent example of what I am commenting on. You will see that the rack pivot point is much closer to the wheel than the track arm pivot point. When the suspension compresses the rack tie rod and the track arm move through different arcs therefore the 'king pin' moves much less to the centreline of the car than the steering arm end, thus it will pull the steering arm inwards causing the wheel to toe-in. If the bump is on one side only the vehicle will turn away from the bump (bump steer).

The position of the rack is influential and difficult to assess without extensive 3-D modelling either by CAD or a physical 3-D model

I suggest you read Allan Staniforths book on the subject for a better and more detailed overview:-
http://www.amazon.co.uk/Competition-Car-Suspension-Design-Construction/dp/185960644X

Xellex
April 15th 2009, 06:52
Man, I can't believe it's been so long since the site went down! Take an average of 20 times a day checking if it's back up, and multiply it to the days passed, and you get a mad man :mad2:

I've made some progress on my bug too. I gave up on the idea of using the Porsche rack, but still, I decided to try someting just a little bit different. More on that later.

I mounted some small stuff on the bug, like a 3rd brake light, some mounts for the front licence plate, that move it under the bumper, I replaced all the brake plumbing, I also replaced that bushing inside the tunnel, for the shifter linkage, I installed the flip-it bushings. Pics in my album, link is in my signature.

And most importantly, my front suspension came, and it's awesome! It's the LA Performance set, for late 944 spindles.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2083.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2083.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2087.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2087.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2094.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2094.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2093.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2093.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2092.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2092.jpg)


And after a long time, the bug can sit on all it's 4 wheels again!

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2103.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2103.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2101.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2101.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2100.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2100.jpg)

If you look closely in the suspension pics, you can see the rack mounts that I'm trying to make, using the original pre '75 steering box mounts. Right now it's only a mock-up.
The rack it's self is from the Audi 100 / Audi A6 Typ 44. It's almost the same as the late 1303 one, but the mounting points are different and the splined shaft has the same diameter, but more splines. The model that I chose also has power steering, but I'm probably not gonna use it.
There are a few little problems that I have to solve somehow but I'm confident it's gonna work.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-02-07%20Alta%20caseta%20-%20mai%20potrivita/th_DSCF2078.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-02-07%20Alta%20caseta%20-%20mai%20potrivita/?action=view&current=DSCF2078.jpg)

jmd
April 15th 2009, 16:15
I am way into this thread. I can't wait to see what comes of the Rack and Pinion setup...

typ4boy
April 16th 2009, 05:57
Man, I can't believe it's been so long since the site went down! Take an average of 20 times a day checking if it's back up, and multiply it to the days passed, and you get a mad man :mad2:

I've made some progress on my bug too. I gave up on the idea of using the Porsche rack, but still, I decided to try someting just a little bit different. More on that later.

I mounted some small stuff on the bug, like a 3rd brake light, some mounts for the front licence plate, that move it under the bumper, I replaced all the brake plumbing, I also replaced that bushing inside the tunnel, for the shifter linkage, I installed the flip-it bushings. Pics in my album, link is in my signature.

And most importantly, my front suspension came, and it's awesome! It's the LA Performance set, for late 944 spindles.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2083.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2083.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2087.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2087.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2094.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2094.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2093.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2093.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/th_DSCF2092.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-17%20Au%20venit%20suspensiile%20fata/?action=view&current=DSCF2092.jpg)


And after a long time, the bug can sit on all it's 4 wheels again!

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2103.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2103.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2101.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2101.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/th_DSCF2100.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-03-19%20Din%20nou%20pe%204%20roti/?action=view&current=DSCF2100.jpg)

If you look closely in the suspension pics, you can see the rack mounts that I'm trying to make, using the original pre '75 steering box mounts. Right now it's only a mock-up.
The rack it's self is from the Audi 100 / Audi A6 Typ 44. It's almost the same as the late 1303 one, but the mounting points are different and the splined shaft has the same diameter, but more splines. The model that I chose also has power steering, but I'm probably not gonna use it.
There are a few little problems that I have to solve somehow but I'm confident it's gonna work.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-02-07%20Alta%20caseta%20-%20mai%20potrivita/th_DSCF2078.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-02-07%20Alta%20caseta%20-%20mai%20potrivita/?action=view&current=DSCF2078.jpg)

Nice struts .

Xellex
April 26th 2009, 15:14
hehe thanks! :D
Actually Lee, I have a small question for you. I just noticed something in a picture of the white bug that you're currently building (which is awesome by the way). It seems like half the bottom of the trunk is raised by a few centimeters. Am I right? Is that something normal for the r&p bugs? I'm asking because looking at my bug, it's impossible to fit a r&p without cutting exactly the part that seems to be raised in your pic.

And another question for everyone that lowered their bugs: what's the maximum suspension travel (when it's compressed) before the lower arms hit the r&p or something else? Do we need to prevent that by using some bump stops on the struts, or it's not gonna happen?

Wally
April 26th 2009, 15:54
And another question for everyone that lowered their bugs: what's the maximum suspension travel (when it's compressed) before the lower arms hit the r&p or something else? Do we need to prevent that by using some bump stops on the struts, or it's not gonna happen?

With a lot of lowering, it eventually WILL hit the mounting ends of the rack & pinion... Don't know what the exact amount of lowering is, but somewhere near 10cm and using type 1 Golf struts (which have a lower casing on the bottom) and shorter bump stops and you'll get there. Not likely for most of us I think ;) Just using normal full length bump stops helped for me.
Thats all I know about this.

Xellex
May 18th 2009, 14:38
Hi guys! I made some more progress since the last update. Now the steering rack brackets are ready, and the rack is on. The brackets are a little thin, so maybe I'll copy them in a thicker material if needed.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/th_DSCF2330.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/?action=view&current=DSCF2330.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/th_DSCF2327.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/?action=view&current=DSCF2327.jpg)

I used the u-joint shaft from a VW Golf, but I changed it's rack-end with the Audi one. In the second pic, starting up to down, late Porsche 944 shaft (and I think it's the same for the late post '75 VW1303), then Golf2, pre '75 1303, and Audi 100.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/th_DSCF2331.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/?action=view&current=DSCF2331.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/th_DSCF2109.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-04-24%20Aproape%20gata/?action=view&current=DSCF2109.jpg)

The tie-rod assemblies are Audi 100 C4. The length is perfect.
I didnt manage to drive it yet because I can't get it out on the street... a mountain of construction sand is blocking my way out, so I have to wait a few weeks.

And I'm in the process of making the power steering work too :D
I mounted an electrical power steering pump, from the Vw Polo/lupo or Skoda Fabia or Seat Ibiza/Cordoba. The pressure lines are in too, I didnt manage to start it yet, it needs some wiring, a sensor mounted on the steering column and a good electrician to sort it all out.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3139.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3139.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3141.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3141.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3143.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3143.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3145.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3145.jpg)

Don't start asking me why I needed power steering.... its a challenge... I just want to see if I can do it :d

Xellex
May 18th 2009, 15:06
and another quick update: I split them like this because the forum says there are too much pics in the same post or something.
I got a few parts from the "Maikaefertreffen" in Hannover:
An original key, and a VW1303 keychain, 4cm widened front fenders from Kerscher Tuning, a front bumper with holes for the turn signals, and some clearglass turn signals, and for the first time since I have the car, Running boards!
Everything is already on the car :D

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3062.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3062.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3113.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3113.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3118.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3118.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3119.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3119.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3122.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3122.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3125.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3125.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3126.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3126.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/th_DSCF3132.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-07%20Chestii%20din%20Hanovra%20si%20pompa%20servo/?action=view&current=DSCF3132.jpg)

"Too many pics" message again haha :p

Ganjalf
May 18th 2009, 15:56
Good luck with the power steering. I hope it works out :)

ABS next? :lmao:

Wally
May 18th 2009, 16:36
It looks twice a good already with that stance. Well done!

evilC
May 20th 2009, 06:47
Hi Xellex,
It occured to me this morning that if you had power steering then there was no real limitation on the amount of caster that you could run. Have you thought about setting it up with say 9-10deg caster? That would provide very stable straight line running together with better loading of the outsde wheel in the turns? Also, I would be expecting better feel to be generated compared with the normal caster setting.
With the weight to the rear and the centre of aerodynamic pressure too close to the centre of the wheelbase, the bug needs all the help it can get to track straight at speed. The higher the speed the worse it gets so with the limitations on the amount of caster that would be acceptable on a manual steering the compromise is in favour of poor high speed stability. With power steering there will be no real practical limitation on how much caster you can dial in.

Wally
May 20th 2009, 06:55
So, does anyone know what the 911's run caster-wise? They later ones are quite stable at speeds :lmao: and might have power steering as well?

Xellex
May 20th 2009, 10:50
Well that's an interesting idea, and I think it might work, but what are the bug's possibilities of caster/camber setting?
I haven't seen too many custom stuff either, designed for this thing. Other than those flanges somebody was selling at the Hannover meeting this year.
I wonder if those are adjustable, or they only have a (higher) preset angle?

evilC
May 20th 2009, 11:33
What about something like this?:
http://www.demon-tweeks.co.uk/products/ProductDetail.asp?cls=MSPORT&pcode=MSLABTM001

Bug@5speed(US)
May 20th 2009, 13:07
Xellex,

I believw GWD in germany use to carry them.. Not sure if they do anymore.

I am not sure if they were GWD orginal, or Remelle or other, but I was also interested in them for my car, but never was able to get a definitive answer..

I was trying to look at the pic, but who was the vendor that is carrying them now (at the show)
VR
Alex

Xellex
May 20th 2009, 17:22
I didn't take that pic, dirk.Gysbrechts did, and I "borrowed" it from the Hannover 2009 topic. Indeed it was the GWD table. I stood there, looking at those fine parts for a good period of time, wanting to get them. But with a limited budget, and something else in mind, I had to pass on those.

Anyway I used my old bug upper flanges on purpose for now, and didnt get new stock ones, because I really intend on getting something with more adjustability.

evilC, the ones you posted are more than interesting, but it looks like you would need some fabrication to install them in the bug. Is anyone here using them?

Bug@5speed(US)
May 20th 2009, 22:17
Xellex,

Looks like I need to talk to a buddy to see if he made a new run..

Thanks for the heads up..

VR
ALex

evilC
May 22nd 2009, 05:23
......................
evilC, the ones you posted are more than interesting, but it looks like you would need some fabrication to install them in the bug. Is anyone here using them?

I don't see why? The plate goes ontop of the strut in the luggage compartment and you just rotate it to select the correct holes for the geometry you need. There is even one quoted for a MK1 Golf (Rabbit) that IIRC uses the same strut as the '03.:)

Wally
May 22nd 2009, 06:12
...a MK1 Golf (Rabbit) that IIRC uses the same strut as the '03.:)

No, not the same. Nothing shares the super strut tops, only the '74 models 412 do.

evilC
May 22nd 2009, 07:29
I stand corrected - thanks. It is however, as I see it a very easy solution:
1) Either the holes match the three stud strut tops OR
2) Use an alternative strut top like the 924S/944 one I'm using and drill two new holes for the 4 stud unit.

(I elected to go with the 944 strut tops as the rubber seating is slightly bigger than the '03 super ones and I reasoned that the fact that they support a relatively heavy front end normally that would present a stiffer strut top than normal)

Xellex
May 22nd 2009, 19:33
well the way I see it, these bearings listed on that website are only a part of the whole.... because looking at the GWD ones, I think you would have to fabricate a thick flange in the shape of the original beetle top mount, and mount these custom parts on that flange, that way making the whole piece. And the way you mount these 2 separate parts together, gives the different suspension angle.

I really don't think you could just bolt that "spherical bearing" onto the bug body, matching it to the 3 stud top holes.

Maybe you could just fabricate that "flange" out of some old original strut mounts, removing the rubber core and drilling some holes in that circular pattern.

I made a quick drawing, maybe it will help understand what I'm saying.

Oh, and guys, please use less abreviations on the forums because it's hard for a non-english native like me to keep up.


And choosing the right one is a question of the inner diameter of that spherical bearing, where the strut rod comes through. The Golf one is probably good. Can someone confirm that for sure?

Wally
May 23rd 2009, 16:37
I made a quick drawing, maybe it will help understand what I'm saying.

Oh, and guys, please use less abreviations on the forums because it's hard for a non-english native like me to keep up.




My (Golf1) shocks have 14mm diameter if that helps?

Nice drawing BTW (By The Way) :D
Oh, and IIRC stands for 'If I recall correctly' ;)
Well, as always, YMMV (your milage may vary) :lmao:

Xellex
May 23rd 2009, 19:19
Hehe, I know the usual ones like BTW or IIRC or IMHO but you guys are using technical abreviations too and I always have to check on google or something, like the thing EvilC said earlier:
"Strut tops OR". What's the OR for? :confused:

later edit:
Ahaha I think I get it! It was Solution 1 OR solution 2... :lmao: :lmao:

evilC
May 26th 2009, 07:21
And it was not an abreviation (abbr.)!

Xellex
June 1st 2009, 15:13
hehe yes, I realised that a bit too late.

Ok I finally got the bug on the road after exactly 1 year since I started working on it. I did more than 1000km during the last week-end. I went to one of the very few romanian aircooled meetings.
The bug worked perfect with the new steering and suspension, everything was great, I am extremely happy with it.

Oh, and I finally got widened rear fenders too, and I also got a nice original leather VW sports steering weel :D

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/th_DSCF3221.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/?action=view&current=DSCF3221.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/th_DSCF3268.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/?action=view&current=DSCF3268.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/th_DSCF3274.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/?action=view&current=DSCF3274.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/th_DSCF3277.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/?action=view&current=DSCF3277.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/th_DSCF3279.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-05-31%20Timisoara%202009/?action=view&current=DSCF3279.jpg)

evilC
June 2nd 2009, 05:06
Nice looking car! Does it have the power steering you were looking at? If so, let us have some feedback>>>>>>.

Clive

NO_H2O
June 2nd 2009, 14:04
Nice ride.:thumbup:

Jim
June 3rd 2009, 05:35
Great pics!!!

zen
June 6th 2009, 11:02
Always good to see another project car hit the road. It's a great looking car. Job well done. Keep us updated.

Xellex
June 18th 2009, 06:46
Thanks guys!


Nice looking car! Does it have the power steering you were looking at? If so, let us have some feedback>>>>>>.

Clive

It has everything installed, but the electro-hydraulic pump is not as simple as I thought at first. Normally there would be a sensor inside the steering rack, that "feels" the movement of the steering wheel, and turns on the pump, to assist you while you steer.
What we have to do now is to adapt a (probably hall effect) sensor somewhere on the steering column, to get the desired signal for that pump.
That's too complicated for me, but luckily I found somebody who can do it.

Otherwise, the steering is great, I did almost 1500Km with the bug now, and I can say I didn't notice ANY bumpsteer at all (and believe me, romanian roads are full of holes, craters, and bumps of all sorts :angry: ), everything seems very precise, there is absolutely NO play in the steering, and it takes just a bit more than 2,5 turns of the steering wheel from lock to lock.

So far I'm happy with it. The only thing I'd like to do is to beef up those rack mounts, just to be safe.

Xellex
July 30th 2009, 03:34
Hi guys, check this out!! I just won this original Riechert cooling setup on ebay! I'm so happy, I had to tell somebody :D

Now I hope it arrives safely to my home, and I really hope I didn't bid against any of the people here on the GL forums.

evilC
July 30th 2009, 07:42
Now if you put it under the motor you will be able to suck yourself down onto the road.:lmao:

Clive

Wally
July 31st 2009, 15:53
Well done! Looks like a very complete set-up.

Xellex
August 11th 2009, 08:45
Today it finally arrived, and everything seems to be ok. Now I have to start writing down a list of stuff to do in order to get the type4 engine working.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/th_DSCF3568.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/?action=view&current=DSCF3568.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/th_DSCF3569.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/?action=view&current=DSCF3569.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/th_DSCF3570.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/?action=view&current=DSCF3570.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/th_DSCF3571.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-08-11%20Kit%20racire%20Porsche%20-%20Riechert/?action=view&current=DSCF3571.jpg)

And in the mean time I wanted to do something better with my headlights, so I ordered another HID kit, I bought 2 secondhand FK Golf headlights, for the clearglass, and I did this:

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_28072009005.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=28072009005.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_28072009001.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=28072009001.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_28072009003.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=28072009003.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_28072009009.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=28072009009.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_28072009010.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=28072009010.jpg)

Xellex
August 11th 2009, 08:56
and this:
http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_30072009001.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=30072009001.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_30072009002.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=30072009002.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_30072009004.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=30072009004.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_29072009.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=29072009.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_29072009002.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=29072009002.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_DSCF3566.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=DSCF3566.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_DSCF3555.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=DSCF3555.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/th_DSCF3553.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/?action=view&current=DSCF3553.jpg)

Xellex
September 3rd 2009, 06:20
Hi guys! Time for a quick update: A few days ago I bought and installed a pair of koni yellow adjustable rear shock absorbers.
I am so happy with these, that I can say for the first time since the porsche conversion, my car has rear shock absorbers! The old ones, and the porsche 944 ones that I tried for a while were not doing absolutely anything.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3907.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3907.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3910.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3910.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3914.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3914.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3916.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3916.jpg)

And I started polishing the porsche cooling system. I want it to look good at least the first time it's on.
Slowly I'm trying to gather everything needed for the type4 engine, and to get to a definitive set-up, but i'm gonna need all the help I can get, since it's my first ever engine build. Hope it will turn out ok.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3570.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3570.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/th_DSCF3575.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-02%20Amortizoare%20spate%20Koni/?action=view&current=DSCF3575.jpg)

NO_H2O
September 3rd 2009, 12:17
Looking good. Keep chipping away at it.

Bogara_ZO
September 3rd 2009, 12:42
Good to see cars like this in the "neighbourhood" (I'm from hungary), congratulations. You should visit one of our VW meetings!

Xellex
September 3rd 2009, 19:45
I sure will! But this year I've been a little short on money.
A few friends of mine went to the Gyoma&Rod on the 7-8-9 august 2009 and they say it was a blast.

Bogara_ZO
September 4th 2009, 08:12
I sure will! But this year I've been a little short on money.
A few friends of mine went to the Gyoma&Rod on the 7-8-9 august 2009 and they say it was a blast.

This year I missed Gyoma, but usually it's a good one. But there are many others you can visit, it's up to you. See you in 2010 :)

Xellex
September 30th 2009, 18:17
Took my car down the road again, for the last aircooled meeting in our country this year.
It handles well, but I'm still not completely satisfied with the rear setup. There is a wierd bouncing effect, after you hit some bump/hole on the road, the rear behaves normally, and after that it just bounces 1-2 more times. It's verry annoying because on some roads wich are not perfectly flat, and at a certain speed, it starts resonating (duuno if that's the correct word to describe it) and the whole rear goes up and down constantly.
This effect was lowered by the new koni shocks but it's still there. Right now the shocks are on the 4th click. (1=softest, 5=harderst). Should I set them to 5th?
The only thing I can think of is that the Porsche 944 torsion bars that I used are not good for this setup (maybe too soft?).
Should I switch back to the original 1303 torsion bars and give it a try? (man that's alot of work) :(
Any suggestions are more than welcome. Thanks.
And a few new pics:

http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/th_DSCF3934.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/?action=view&current=DSCF3934.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/th_DSCF3937.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/?action=view&current=DSCF3937.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/th_DSCF3957.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/?action=view&current=DSCF3957.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/th_DSCF3962.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/?action=view&current=DSCF3962.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/th_DSCF4032.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2009-09-30%20Intalnire%20Bran/?action=view&current=DSCF4032.jpg)

Wally
October 1st 2009, 02:51
4th round in is already a lot for Koni's. The thicker torsion bars (23,5mm) from the 944 are very good and definately not too stiff. I use them as well and almost considering even bigger (25mm?)
There must be something else wrong...

You definately describe a too soft shock problem, so I am confused as well.
I use Bilstein gas shocks at the rear and Koni red up front. Very happy with the rear Bilsteins, they seem to have more rebound resistance. Maybe thats needed more at the rear?

Jim
October 1st 2009, 04:02
Check how low is the rear suspension and if the bumpstop hits the upper end of the body.

If this happen then it should give you this extra 1-2 bounces.

I agree with Wally's thought, bilsteins + 23.5 944 torsions are one of the best choices!

Wally
October 1st 2009, 04:50
+1 on shortening of the bump stops after lowering. Didn't think about that one, but it sure sounds like the cause of your problem.

evilC
October 1st 2009, 07:29
I'm with Jim and Wally on this one especially confirming that you have a good rear specification. It seems as if the springing is overcoming the damping by a serious amount. Looking at your photos the rear end does not look too low and I see that you have polyurethane bumpstops mounted on the upper bracket rather than the alloy trailing arm but that should not make any difference. i would expect about 40mm+ clearance on the bumpstop at least in the static position. Are the Konis new? and do they work? It has been known for even new dampers of Koni's quality not to work properly. Have you a photo ofv the rear suspension in the static position with the wheel on the ground?

Clive

Xellex
January 16th 2010, 12:32
Sorry for the very late reply. So, to give a few answers, the rear is not lowered too much, but still, it is. Today I managed to take a few pictures in a static position, just like you said, but I don't think they are too conclusive. I will try and measure the clearance on the bump stops:

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4418.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4418.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4424.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4424.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4431.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4431.jpg)

The konis are brand new, out of the box, and they seem to be working good.
From what I understand, you guys think the car is riding on it's bump stops, and only going up/down on it's tires right? That could explain why this effect was a bit atenuated, after I changed the wheels/tires from 195/65R15 to 215/50/17. Lower profile - lower room to bounce around.
So I'll try and get a measurement, and maybe cut the bump stops shorter.

And for the news: I managed to get a set of 17" Porsche cup3 Turbo twists!! I'm so happy, this was the set of wheels I wanted eaven before I had the bug!!! I got them on the car, with 215's in the rear, and 205's in the front. I was pleased to realise that the 215's fit in front very well, and I could go eaven wider.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4433.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4433.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4434.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4434.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4437.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4437.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4443.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4443.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4444.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4444.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4446.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4446.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/th_DSCF4417.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-01-14%20Jante%20Porsche%20Cup3%20Turbo%20Twist/?action=view&current=DSCF4417.jpg)

Wally
January 16th 2010, 13:28
She's got the stance and looks hot!
But how does she drive in extreme circumstances?

Xellex
January 16th 2010, 18:32
Well, the biggest problem is that we don't have a circuit here in Romania.... The second biggest problem is that everytime I do something to my car, it gets less and less practicable on the normal roads, with all the holes, and bumps.... But when you get a few km's of good twisty mountain roads, it's a pleasure. It's like glued to the asphalt, the steering is great also, but it desperately needs more power. And on a straight line, I took it to 160+ km/h with everything stable and good, on the highway, but I think that's all the poor old 1,6 engine can do, eaven with dual webers.

Hope I can throw a type4 engine in this year, but I'm also getting married this year, and that comes first. And I hope I'll solve that bouncing problem in the rear, because it's annoying.

Steve C
January 16th 2010, 20:01
Hi

What sort of tyre pressure are you running, this can make huge difference on the way bug feels over potholes etc?

I'm running 20-22 front and 26-28 rear.

Steve

Jim
January 17th 2010, 14:03
Excellent choice the Twists Xellex! They are my favorite too because it gives the beetle an outstanding finishing....!!!

From the photos seems that the bumpstop is too close in the trailing arm and i assume that this is your problem.
Before you cut it,just remove it and take the beetle for a ride to see if it repeats the problem again.If not then cut the bumpstop at least the half and you will be ok:D

Steve,
This tyre pressure it is for 17" rims? Because i use for mine 30 for rears and 26 for the fronts, but i dont know if it's the correct one..

Steve C
January 18th 2010, 01:40
Hi

That the pressure I use with 17x7s and I've also used it with 17x8 & 9s as well.

Steve

Jim
January 18th 2010, 03:22
Thx for the update Steve!

Steve C
January 18th 2010, 04:39
Hi Jim

No worries, I would like to hear others thoughts on tyre pressures.

Steve

Xellex
January 19th 2010, 18:29
Guys, I found this mercedes w123 oil cooler, and I know what you said they are very good for the type4 engines, but this particular one seems to me that is too small for use at least without the stock type4 one too.
I measured 26x9x6cm. Think I should get it?
Found a better picture of it on the web too:

Wally
January 20th 2010, 04:26
It is supposed to be a transmission cooler, that WE use for oil cooling...
That isn't it...

Xellex
April 11th 2010, 20:00
hi guys! Check out what I ran into:
I found this Porsche 911 Carrera that was involved in an accident some years ago, and I thought I could use some parts off it, so here I am, the owner of a 911 for the first time in my life :p
At first, before I bought it, I made a mistake when checking it's serial numbers, and I thought it was a 1987 G50 one, but it turns out it is a 1985 carrera 3,2l, 231hp, with a 915 gearbox.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4004.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4004.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4007.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4007.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4008.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4008.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4009.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4009.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4022.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4022.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4031.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4031.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4032.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4032.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4041.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4041.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4059.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4059.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4075.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4075.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4080.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4080.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/th_DSCF4081.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-04-09%20Primul%20meu%20porsche%20911/?action=view&current=DSCF4081.jpg)

The engine turns freely, and is complete, but I won't keep it for myself. Gonna try and sell it to get some of the money back. The same goes for most of the parts other than the gearbox and maybe the gauges.


And the second thing that I ran into: a picture of my bug taken in 1993 by a previous owner. I knew the bug was white in it's original shape, but I have never seen it like that until now..

Xellex
April 19th 2010, 05:45
I put the car's serial number in the Porsche PET catalogue, and this is what it gave me:

Model designation: Carrera Cabrio
Model: 911
Year: 1985
Engine code: 930.20
Transmission code: 915.72
M codes:
M197 Stronger Battery
M220 Locking differential 40%
M395 Light alloy rims, forged, 16 inch
M533 Anti-theft device
M567

Now, the question is, does this mean the gearbox has a LSD unit installed?

Wally
April 19th 2010, 07:37
Yes, congrats! But that should also be visible on the tranny itself where the type 915/72 is stamped in (underside, lowest bottom rib) by the addition of '12' with that code. So, should read s/th like 915/72-12 according to porsche's own publications wrt tranny numbers.

40% is quite a lot. Must have been a very sporty driver to order that much.
Most LSD's have worn a lot though, but can be renovated with new disks.

Blizzard
April 19th 2010, 10:08
Hello, I almost have the same rear suspension setup as you have. I've almost made the mistake to mount the right Torsion Bar on the left and the left on the right. Do you know for sure that they are on the correct side off the car?

Great looking car by the way. I use the 944 S2 TB's and also yellow Koni's.

Xellex
April 19th 2010, 11:25
That came to my mind a while ago, but I went thru all my build pictures, and tried to remember exactly what I did, and now I'm 90% sure I didn't mistake the L-R sides. Anyway first time I take them off, I will double check that. From what I remember, they should be stamped L and R.

Xellex
April 19th 2010, 11:28
Yes, congrats! But that should also be visible on the tranny itself where the type 915/72 is stamped in (underside, lowest bottom rib) by the addition of '12' with that code. So, should read s/th like 915/72-12 according to porsche's own publications wrt tranny numbers.

40% is quite a lot. Must have been a very sporty driver to order that much.
Most LSD's have worn a lot though, but can be renovated with new disks.

That's cool, I will also check the code stamped on the tranny. One more thing I noticed: it has a transmision oil cooler, did all of them have that? And do we use it in the bugs or just remove it and close the circuit?

wrenchnride247
April 19th 2010, 21:49
That's cool, I will also check the code stamped on the tranny. One more thing I noticed: it has a transmision oil cooler, did all of them have that? And do we use it in the bugs or just remove it and close the circuit?

The cooler is an "upgrade" it helps with higher HP engines, or heavy track use. If you stay under 280 HP you shouldn't need it. ;)

Xellex
April 27th 2010, 07:01
I just realised I didn't update the topic back a few weeks ago when I went to the biggest anual tuning show in Bucharest. Me and a friend of mine who owns a yellow 911 carrera represented the aircooled division of my club (anonymous motorsport). He won 2 prizes (best oldie with his Porsche and best import with his Nissan 350Z Veilside). I took alot of pics, most of them not aircooled related, but still interesting to some:

For the entire album from that event click HERE (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/)


http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4001.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4001.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4002.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4002.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4005.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4005.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4009.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4009.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4011.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4011.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4012.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4012.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4013.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4013.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/th_DSCF4024.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-03-14%204Tuning%20Days%202010/?action=view&current=DSCF4024.jpg)

Xellex
May 19th 2010, 19:26
I've been working on my car again lately, and I'm pretty happy with the result:
I cut off the whole dashboard off the wrecked 911. Much more than I needed in the end but it took a bit of fitment and cutting till the finished product.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4418.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4418.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4420.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4420.jpg)

Than I took off the beetle dashboard, and I ended up with these:

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4424.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4424.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4425.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4425.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4427.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4427.jpg)

Which in the end I combined into this :P

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4429.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4429.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4433.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4433.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4434.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4434.jpg)

A friend came with the idea to take the leather off the dashboard face and paint it blue. I think it came out nicely.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4442.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4442.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4447.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4447.jpg)

It took me 2 days to do all the wires (no electrical experience whatsoever) but I managed to do it right. This is the finished dashboard, both in daylight and by night:
I couldnt get the tachometer perfectly centered above the steering wheel, because I kept the lateral vents functional, and I will adapt the center one too. It still needs some finishings, the electronic speedometer will not work until I will install the 915 gearbox, I have to install the oil pressure and temperature senders, and the tachometer is set for 6cylinders, which I will have to adress. Everything else works as it's supposed to. I want to get a vdo voltmeter to replace my old tachometer.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4460.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4460.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4507.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4507.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4513.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4513.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/th_DSCF4519.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-05-14%20Bordul%20de%20porsche%20911/?action=view&current=DSCF4519.jpg)

So what do you guys think? :D

NO_H2O
May 19th 2010, 20:42
Nice job.

wrenchnride247
May 19th 2010, 21:32
That looks like it could of come that way from the factory! :cool:

Xellex
May 28th 2010, 18:07
I have also been working for a while now on a EDIS4 + Megajolt setup, that I want to use on the type 4 engine if that's ever gonna get finished, and it's working good now... I have made about 400km's on it already.
I also made and installed a small shift-light.
Took a video of the dash. I'm planning on modifying the 911 tach to show the real RPM, but it works for the moment. Just have to multiply by 1,5... I guess I exercise my mind that way too :P

http://www.youtube.com/watch?v=oWQDJH6xVZA

I have to change the engine mounts, they are completely toast. That's the knocking sound. I ordered those yellow "Rhino" mounts and I'll change the cradle to the early style. Anyone using them? Are they worth it?

Wally
May 29th 2010, 04:40
I ordered those yellow "Rhino" mounts and I'll change the cradle to the early style.

Anyone using them? Are they worth it?

No, euh, no.. imho.
I have always used the original VW, high-duty rubber, old-style cradle mounts. There are two types in the black original stuff: stock and HD. The HD is plenty if you have something else (for example GB tranny support mount) to prevent torsional movement of your engine.
Sorry, haven't got the part nr. ready for ya...

BTW Dash looks cool!

Xellex
September 8th 2010, 20:02
I couldnt resist, so I bought another set of wheels... They looked so yummy :yumyum:
I still like cup3's more, but these are in much better condition than mine. Hope they will look nice on the car :D

Jim
September 9th 2010, 07:03
I couldnt resist, so I bought another set of wheels... They looked so yummy :yumyum:
I still like cup3's more, but these are in much better condition than mine. Hope they will look nice on the car :D

I bet they did!!!

Humble
September 9th 2010, 13:06
Looks like a good buy to me! I'd like to say i've never done this but I have, a lot :D Are you going to get these on the car soon or hold out until after winter?

Xellex
September 10th 2010, 11:23
it's probably a great idea to keep the old ones on the car until spring...

Today I sourced a set of new upper strut flanges. It's the older model (pre '73). And a Topline Parts strut brace :D
I started installing them, and as I almost finished on the left side, the bearing came out of the rubber sleeve, and it seems nothing is holding it in place AT ALL. I have read about this over at superbeetlesonly, and it seems that's the way they make them, but it doesnt feel safe at all to me. On top of that, if I lower the car back on it's wheels, the bearing moves up and comes out of the rubber, into the luggage compartment :))

So, I had this idea, inspired by the uniball flanges, to just weld the bearing onto the flange, after cleaning the rubber off. I know it's not a uniball bearing, and it only moves on 2 axis, but I think it's better than the stock flanges which are usefull at the moment.
Gonna give them a bit of camber and caster while I'm at it.
Pics soon, I didn't have a camera with me.

Any idea why I should't do this? Is it a bad thing?

Xellex
October 7th 2010, 18:55
A few days ago, I took the engine and the tranny off, as I'm not going to drive the car during the winter, so this gives me time to try and install the 915 gearbox.
I'm trying to do this on a budget, so I'm going to use what I already have, as much as I can.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_28092010006.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=28092010006.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_28092010004.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=28092010004.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_28092010003.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=28092010003.jpg)

The clutch part is a puzzle, and I'm lucky with all the info on this forum, otherwise I wouldn't have had the courage to take on a project like this.

So, this is what I already had: A 915 pressure plate, a 915 good used disc, a bus 228mm flywheel, pressure plate and disc.
The bus disc is useless ofc, and I tried the 915 disc in the 228mm bus pressure plate but it will never fit.

Today I sourced one of those Lancia 228mm discs that have been discussed about here, and it seems perfect. I alligned it's center with the porsche one, and it's a perfect match. Haven't tried it on the gearbox yet. Oh, and it fits inside the 228mm sachs pp :D

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_07102010010.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=07102010010.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_07102010011.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=07102010011.jpg)

I also welded and redrilled the 915 flanges for the 944 drive axles.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6081.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6081.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6083.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6083.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6082.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6082.jpg)

also, the new wheels and the topline strut brace are in :D

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6087.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6087.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6088.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6088.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6085.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6085.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/th_DSCF6060.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-10-08%20%20Dat%20jos%20cutia%20si%20motorul/?action=view&current=DSCF6060.jpg)

Xellex
December 18th 2010, 18:39
Hi guys, the 915 gearbox is installed into the beetle, finally. I widened the original porsche front mount, and made some brackets for the rear craddle, inspired by pictures of Wally's old 915 install.
I didn't take any pictures yet, but I will. I still have alot to do untill it's gonna work, but I'm making progress.

Now here's something funny:

While I was at it, I was wondering if there's any OEM 200 mm clutch disc available on the market, to fit the original 1.6 beetle engine to the 915 gearbox, and it turns out there is!!!
I went through the Sachs online catalogue and discovered alot of cars use this type of disc! Like Fiats, Seat, Lancia, Moskwitch, and Lada! :))
So I bought one of these discs, to try it on and it perfectly fits both the gearbox and the beetle flywheel/pressure plate!

Other than that, I've been gathering a bunch of shiny parts for my type4 engine, but I'm still far from installing it in the bug.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_15112010073.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=15112010073.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7385.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7385.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7398.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7398.jpg)

I'm so happy I got this dry sump tank on e-bay for about 90Usd incl. shipping! So the new engine will be dry sump :)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7408.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7408.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7409.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7409.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7411.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7411.jpg)

And today I sourced a new original Kamei spoiler for an awesome price, and I couldnt resist buying it, eaventho my bug is probably too low for it. I'm thinking about raising it a little maybe...
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7421.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7421.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7422.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7422.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/th_DSCF7424.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-02%20Cateva%20piese%20pt%20motorul%20tip4/?action=view&current=DSCF7424.jpg)

Wally
December 19th 2010, 07:14
Good progress! I like the pic with the label saying: 'Hochstgeschwindigkeit': 'Ohne Beschränkung' :D

dub_crazee
December 19th 2010, 07:24
nice work on the clutch plate.

so many clutch plates cross over - im goin to hunt through for one suitable for my set up as im sure itl work out cheaper than a kep one! lookin forward to seein pics!

Deano

Xellex
December 27th 2010, 19:23
Recently I have moved my bug and most of my tools to a bigass garage that a friend of mine has rented. (also aircooled owner and fan) and I keep forgetting to take my camera with me when I go there to work on the bug. I'll try to remember. In the meantime I took a few pics with my phone:
The bellhousing is about 2,5cm off to the rear measured from the trans craddle. I forgot to measure the original one, so I don't know how it sits compared to orig. position.
The disc you see in there is the lada one, I was telling you about earlier.
The drive axles are not bolted to anything and that's why they sit so low.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/th_27122010111.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/?action=view&current=27122010111.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/th_27122010110.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/?action=view&current=27122010110.jpg)
And the gearshift lever. It was in pieces when I got it, and it was a pain to get it all assembled but I managed.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/th_27122010109.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/?action=view&current=27122010109.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/th_27122010108.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2010-12-28%20Ultima%20suta%20de%20metri%20in%202010/?action=view&current=27122010108.jpg)
It's probably not the nicest install, but I only hope it's going to be functional.

Bogara_ZO
December 29th 2010, 05:39
I'm so happy I got this dry sump tank on e-bay for about 90Usd incl. shipping! So the new engine will be dry sump :)


Nice progress here:)

I have a dry sump pump, that I've bought from ebay (from your country by the way;)) but changed my mind (won't use the car on track days) so will sell it. I can send you some pics, just let me know if you are interested.

Xellex
December 29th 2010, 07:24
really? That makes me wonder who the hell is also playing with these things in secret... Because our aircooled comunity is so small here, that I could say I know almost everyone related to bugs and buses in my country.
So yes, I am interested, but is it a real dry sump pump or maybe the automatic gearbox beetle pump? Some pics would be great, in this topic or to my email adress: alexsimionro@yahoo.com
Thanks!

Xellex
January 16th 2011, 20:04
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_03012011113.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=03012011113.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_03012011114.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=03012011114.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_03012011115.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=03012011115.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_03012011116.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=03012011116.jpg)


Still working on the gearbox install. I lengthned the porsche rod and bought new bushings for it.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_03012011112.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=03012011112.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_DSCF5333.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=DSCF5333.jpg)

The bushings in the coupler were worn, so I decided to have them made out of urethane:

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_DSCF5332.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=DSCF5332.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_13012011125.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=13012011125.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_13012011126.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=13012011126.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_13012011128.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=13012011128.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_13012011129.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=13012011129.jpg)


I made a flange and a plug to use instead of the oil pump and cooler.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_12012011122.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=12012011122.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_12012011124.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=12012011124.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/th_12012011123.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-01-12%20Tot%20pe%20la%20cutia%20de%20viteze/?action=view&current=12012011123.jpg)


And I changed the type1 CV joints on the gearbox side to the Porsche 944 ones, and I mounted the CV flanges back on the gearbox.
Please excuse the poor quality pics. Still alot to do left, but I ordered a HD gearbox craddle and a CSP Kaefer CUP brace, and I can't do anything untill they arive. I gave it alot of thought, because of my limited budget at the moment, but decided to do it right eaventho it means delaying driving the car..

Xellex
February 9th 2011, 13:32
Yay! Today I got a package from Santa! with a small delay but no biggie :P
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5402.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5402.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5401.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5401.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5400.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5400.jpg)

Xellex
February 12th 2011, 09:01
And it's all fitted on the car already! :D
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5412.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5412.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5413.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5413.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/th_DSCF5414.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-02-09%20CSP%20Kaefer%20Cup%20Brace%20si%20jug%20HD/?action=view&current=DSCF5414.jpg)

dub_crazee
February 13th 2011, 14:02
Been busy!!!

Xellex
March 6th 2011, 12:37
I'm finally almost ready with the gearbox install. I've been trying to sort all the final details out.
I machined the 911 starter, by taking 4mm out of it's mating flange. From my understanding 5mm are needed, but I wanted to be safe and not to leave those 2 brackets too thin. Hope it's gona be enough.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_01032011146.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=01032011146.jpg)
I modified the original porsche guidance tube to accept the bug throw-out bearing. It came out quite nice.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_02032011147.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=02032011147.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_02032011148.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=02032011148.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_02032011149.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=02032011149.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_02032011151.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=02032011151.jpg)

I reversed the shift fork , re-routed the cable guide inside the tunnel to come out on the right lower side, instead of the original left upper position. Used a bug clutch lever. I wanted to go hydraulic but my budget doesnt allow it yet...
Everything fits well, but the bearing throw that the max pedal gives is immense or so it seems to me. I think I either have to lenghten that cluth lever, or make some sort of adjustable stop on the pedal.

And I've bought one more type4 engine which I intend on using for this season. It's a 1.7L. I replaced the pistons with domed ones. And I'm slowly mounting all the accesories on it. Hope to have it running in a couple of weeks.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_04032011155.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=04032011155.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_04032011156.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=04032011156.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_04032011157.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=04032011157.jpg)

Wally
March 6th 2011, 13:41
An original Riechert kit. Nice!

Xellex
March 6th 2011, 15:40
yeah, it's the one I have bought on e-bay a couple of years ago and as of today, the kit is completed by a set of riechert air-filters and linkage that I have juuust won on e-bay :D :D :D
I can't wait for them to arrive!

dub_crazee
March 6th 2011, 16:35
nice progress dude! did you machine off the starter where the 2 bolts go through?

ive finally got the box i wanted which comes with clutch so cant decide whether to get a conversion flywheel or same route you;re goin!

Xellex
March 6th 2011, 18:56
yes, I took 4 milimeters off it, so it will go by that measurement more inside the gearbox bellhousing, towards the flywheel ring gear. I remember the user Tomac here on the forums was saying that you could/should use a hi-torque IMI starter, and machine 5mm off it. But in my case, having the original 911 starter, I thought about trying to modify it instead of buying another one.
If I remember correctly, those 2 brackets with the bolt holes, are 12mm thick. By taking 4mm off, it still has plenty material left to stay strong.
I don't know if it engages the ring gear well, but this week I'm gonna try to mount the flywheel, disc and press.plate on the engine, and then do some measurements.
The one thing I'm a bit concerned about is that the pressure plate would go too far inside the bellhousing when mounted on the engine, and hitting the release bearing. But that too has to be measured first.

About the conversion flywheel, I took it into consideration, because I already had a very good 915 clutch disc, pressure plate and release bearing. But it seems more complicated and more expensive for the long run. I just hope it's gonna work in this configuration, and maybe go hydraulic in the future.

Xellex
March 29th 2011, 19:37
Today I drove the car for about 100 meters. I did it at idle, with no linkage on the carburetors, no acceleration control. I was curious if the gearbox is working, and it does! I only shifted trough 1st, second and reverse and everything seems ok. The clutch engages good, the starter motor works perfectly. Then I placed the car on jack stands, and shifted through all the 5 gears. As far as I can tell for now it works! :D
Now I can concentrate on the engine more. I have this compression loss and oil leak between the cylinder and head at the piston no. 3, and probably have to flycut the heads to fix it...

A few new pics (sorry for the poor quality):
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_14032011160.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=14032011160.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_18032011164.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=18032011164.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/th_29032011178.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-03-05%20Cutia%20este%20aproaaaape%20gata/?action=view&current=29032011178.jpg)

Xellex
April 13th 2011, 01:08
The bug is back on the road again! :D :D And I can say that it's a different kind of animal! I just love it! I made about 200 kilometers with it (in and out of town) and I pushed it so hard that I managed to run out of gas :))
There are alot of small things that I still have to do, adjustments etc but the hardest part is behind me right now :D
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th_untitled.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=untitled.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th_216452_209568775737586_100000533960504_793185_4 996420_n-1.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=216452_209568775737586_100000533960504_793 185_4996420_n-1.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th_untitled2.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=untitled2.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th_untitled1.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=untitled1.jpg)
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th__DSC0001.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=_DSC0001.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/th_untitled3.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-04-13%20Din%20nou%20pe%20strada/?action=view&current=untitled3.jpg)
Oh, anybody know a good online source for AN fittings and hose preferably in Europe? I can't seem to find any in my country...

Wally
April 13th 2011, 04:36
It just looks so right! Very nice! but pls get those case ventilation pipes on the air filters connected to a breather box as your pulling in unfiltered air right now.

Xellex
April 13th 2011, 15:54
yeah, I have the large CSP breather box, and I also drilled and installed fittings in the valve covers, but I rushed to make the car fuctional for that week-end meeting, so I didn't have time to do everything right. I actually worked continuously one full day and a night, till 9 in the morning to get it done :P
Now I will concentrate on the details, I also want to make it Coil-on plug, like slowtwitch did on shoptalk. And a few other things.
I could really use some good oil fittings and hose for the oil cooler... probably AN, because the hose I have atm just doesn't want to stay put on the fittings with just clamps. Maybe if I get it crimped it will stay :P

Wally
April 13th 2011, 16:16
Almost forgot: there is: http://www.isa-racing.com/katalog/
and over here www.racershardware.nl retails these parts. Very high quality, no chinese copies!

Gerrelt
April 13th 2011, 16:23
Cool car, nice color too.:thumbup:

Xellex
May 17th 2011, 19:52
thanks! Let me show you what I've been upto since the last update:
I revised all the wiring in the engine bay. Took out alot of not needed wiring. Mounted the voltage regulator where it's supposed to be. I made a small relay and fuse panel to have everything more organised.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5466.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5466.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5459.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5459.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5470.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5470.jpg)

I converted it to coil-on-plug using the method I have read about on Slowtwitch's topic on shoptalkforums.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5462.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5462.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5463.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5463.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5469.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5469.jpg)

I made a small vacuum collector for the MAP sensor:
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5475.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5475.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5476.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5476.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5480.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5480.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5490.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5490.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5491.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5491.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5497.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5497.jpg)

I installed the crankcase ventilation system.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5498.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5498.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5499.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5499.jpg)

And after about a month, I started the engine again. Now it runs on COP wasted-spark. A small video:
http://www.youtube.com/watch?v=ARQdv55OuA8

dub_crazee
May 18th 2011, 14:10
nice work! Might take a gander @ slowtwitch's topic sounds interesting!

Xellex
May 18th 2011, 17:38
yeah it's quite simple and for me, just like everything I do to my bug, it was a challenge making it work. And it started the first try, I actually managed not to screw up anything.
Here is the topic with the description and schematic of the system:
http://shoptalkforums.com/viewtopic.php?f=1&t=131344

Xellex
May 20th 2011, 20:52
Hehe, I have another update already :D
I've started to understand relays a bit better, so I decided to take on a bigger challenge, and it worked! My beetle now has intermittant wipers with a programmable delay, and a wash/wipe function. I've been meaning to do this ever since I bought the beetle, and now thanks to Joel on aussieveedubbers, I found out exactly how to do it.

http://www.youtube.com/watch?v=aa0N-FMkFjI

I also installed a buzzer relay that goes on when you leave the headlights on, and open the door.

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5692.jpg (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5692.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5689.jpg (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5689.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/th_DSCF5696.jpg (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-05-13%20Instalatia%20electrica%20si%20alte%20detalii/?action=view&current=DSCF5696.jpg)

wrenchnride247
May 21st 2011, 14:29
Love the wiper delay! Looking at something like that for mine. More info please :D

dub_crazee
May 21st 2011, 15:54
ditto that - ive some some room for some more relays :p

Xellex
May 21st 2011, 16:03
Joel did an awesome job on his "how to" topic on aussieveedubbers.com, and eaventho he drives a 1303 super beetle, he put out information for doing it on any other type of beetle as far as I can tell.
Here's the link to that topic, with all the info you will need. And my example is proof of that.
http://forums.aussieveedubbers.com/viewtopic.php?tid=86544

ricola
May 21st 2011, 16:29
With all this talk and being in the middle of doing my wiring I went down to the scrapyard and got myself a '99' out of a 1995 Golf CL today!

wrenchnride247
May 23rd 2011, 20:23
Thanks for the link Xellex ;)

Xellex
August 1st 2011, 18:25
Ok, the 1700 engine was at the end of it's lifetime for sure, eating up oil and smoking like a locomotive, because of the badly worn out cylinder set, so I have decided to change plans on the 2L project, and just build a decent new-ish reliable engine, so I could enjoy my beetle more, and with no worries. The 1.7L engine will now become the long term "all-out" project, and in the meantime, I hope the bug will be running perfectly good. I wonder why I didn't think this up earlier...
That being said, the new engine is already up and running, I did the break-in and about 400 kilometers on it already.

The engine specs are:
2.0L type4 CJ case, with the plugs drilled and tapped.
2.0L crankshaft & rods.
New Mahle main/conrods/camshaft bearing sets. New connecting rod bushings.
Webcam 86A camshaft & matching webcam lifter set.
Original oil pump.
Original 2.0L Piston&cylinder set, honed and re-ringed.
1.8L heads (41x34 valves), just a little bit ported on the exhaust side, and new exhaust valves installed.
1.7L rockers, with the 8mm adjusting screw and the hydraulic shims/spacers instead of the spring.
Scat HD dual springs with the little spring removed.
Pauter HD spring retainers and hardened locks.
Elephant swivel foot adjusters.
228mm clutch.
All the rest, like cooling system, carbs, linkage, ignition system etc, comes from the previous engine.
Right now the exhaust is a hacked up original bus one, but not for long

I'm actually pretty happy with how the engine is performing, the only problem I had was with 2 elephant foot adjusters which exploded (on the same piston), probably because of me not clearancing them well enough. I changed those with original style, and no other harm was done.
I safely took it to 170km/h and it feels like it can do more :D

http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6108.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6108.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6110.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6110.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6119.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6119.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6126.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6126.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6130.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6130.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6131.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6131.jpg)

Here's a pic that I find funny:
I can honestly say that I have a 911 connecting rod in my engine. And a 930 one also :P
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/th_DSCF6121.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-08-01%20Motorul%20type4%202000cmc/?action=view&current=DSCF6121.jpg)

Xellex
September 13th 2011, 13:53
I got a set of gsx-r throttle bodies today :D I'm hoping something nice will come out of these... I'm so eager to start the EFI conversion on my engine! I just love the challenge of always doing new stuff, things that look very complicated (if not imposible) in the begining, and all that it takes until you succeed.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/th_DSCF6733.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/?action=view&current=DSCF6733.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/th_DSCF6732.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/?action=view&current=DSCF6732.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/th_DSCF6735.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/?action=view&current=DSCF6735.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/th_DSCF6734.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/?action=view&current=DSCF6734.jpg)

al_kaholik
September 14th 2011, 11:53
Which ones did you get? 600s? or 1000!

Xellex
September 14th 2011, 15:05
actually these are from a 98-99 GSX-r 750. I searched all the topics and pictures I could find about the difference between engine types and years, and I think this model will fit best. That's because of the better injector angle, and the fact that they are 4 separate pieces, making it easy to space them apart for the IDF pattern.

al_kaholik
September 15th 2011, 03:55
Excellent. I did look at GSXR ones but found a better fit for what I wanted. Are the 750 the tapered 40mm-36mm ones? or are they a straight bore ones?

Xellex
September 15th 2011, 04:25
yes, they are tapered from 48mm to 40mm. I didn't measure the throttle plates but they are probably 46mm.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/th_DSCF6740.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2011-09-13%20Corpuri%20de%20clapete%20injectie%20Suzuki%20 GSXr/?action=view&current=DSCF6740.jpg)

al_kaholik
September 15th 2011, 05:55
:D should make some nice power! What EFI are you looking to use? Megasquirt?

Xellex
September 15th 2011, 14:28
yeah, I think the best choice in my case is going to be a Megasquirt ecu.

Xellex
January 19th 2012, 22:32
I'm tinkering again with the electronics in my car. First of all I managed to get the tacho to read the RPM correctly, thanks to a Dakota Digital universal tachometer adapter, recommended by Dave (owdlvr) in another topic here on GL:
http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-01-20%20Diverse%20pe%20la%20instalatia%20electrica/th_prd_zm_127.jpg (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-01-20%20Diverse%20pe%20la%20instalatia%20electrica/?action=view&current=prd_zm_127.jpg)
Thanks for that!

And after that I took on a bigger challenge: I got a universal central locking remote controlled unit, and this is how far I got today:
http://youtu.be/uQvVb8rrtqg
All that's left now is the mechanical part... installing the actuators etc.

While working on the wiring I stumbled upon a problem: The fact that the bug has a single bulb in the dashboard for both left and right turn signals. And that's run by a wire coming from the relay. That was messing with the central locking, and I managed to change it. Now it's much better and the interesting thing is that the battery voltage is much more stable now and the gauges are not dancing in the flasher's rythm anymore.

http://youtu.be/fjszkigvtjE

And while I was at it, I remembered Joel saying on the auusie forums that there's an accesory position inside the ignition switch. I wanted to test that, and after installing a missing wire, it works now. That opened up some new posibilities for tinkering :P

http://youtu.be/SOey4ggivus

Supa Ninja
January 20th 2012, 00:42
Sweet, I'll be staying tuned to see how you make those gsxr TB's work.

al_kaholik
January 20th 2012, 03:34
Some good work. The cl system looks a lot like the one I have to install on the bug. And the 'x' position on the ignition switch will be invaluable, I'm thinking that you xuls alao put things like the fuel pump priming pulse on it too. I'll be using a relay off it to push to an accessory circuit and fuses.

The very simple wiring diagram I started with got very complicated!

Joel
January 20th 2012, 06:22
And while I was at it, I remembered Joel saying on the auusie forums that there's an accesory position inside the ignition switch. I wanted to test that, and after installing a missing wire, it works now. That opened up some new posibilities for tinkering :P

http://youtu.be/SOey4ggivus


So simple yet so effective.

KaferChris
January 21st 2012, 15:19
Perhaps cooler than the key contacts, there's another Dakota Digital module that controls the headlights/domelights/and gives you retained power without presence of the key...Built-in battery voltage monitoring, adjustable timers, adjustable light sensitivity for automatic headlights, etc.

http://img.photobucket.com/albums/v212/KaferChris/Project%2069/IMG_1938.jpg~original

al_kaholik
January 21st 2012, 16:10
So auto headlight and control of the courtesy light?

Courtesy light I'm going to use a Ford yellow relay. Auto headlights aren't something that I've thought about

What Does the retained power do?

KaferChris
January 21st 2012, 20:18
http://www.dakotadigital.com/pdf/PAC-1300.pdf

Retained accessory powerThe retained accessory power feature allows the accessories to be operated for up to 20 minutes after the key is turned off. These accessories may include the radio, power windows or any other accessory placed under the module’s control. If a door is opened before the 20 minutes, the power to the accessories is removed.

Xellex
January 21st 2012, 20:46
that's very interesting but I just got a few modules from the local market, and they will cover most of these things. I'll post them as I go ;)

KaferChris
January 21st 2012, 23:23
that's very interesting but I just got a few modules from the local market, and they will cover most of these things. I'll post them as I go ;)


Excellent, just noticed you were using the other DD product and doing similar projects - I'll be looking forward to seeing the other options available. :goodjob:

Xellex
February 7th 2012, 22:57
It's so damn cold outside for a few weeks now, that I really can't do much but sitting in front of the PC, so I'm working on a side project. Hope you guys will like it:
www.vw1303s.com

Xellex
July 23rd 2012, 19:43
Finally, I finished my exhaust header. Don't laugh at me too hard, it's my own design, and I worked with the tight space I had under the bug.
http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_18072012541.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=18072012541.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_26062012523.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=26062012523.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_18072012540.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=18072012540.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_23072012544.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=23072012544.jpg)
I't all stainless, with equal length primaries, and merged according to the firing order.
The muffler is from some motorcycle (yamaha R1 I think).
Welded the bungs and soon I'll have a wideband O2 system and EGT reading :D
http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6114.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6114.jpg)
Drove it a few km's tonight and as far as I can tell, my bug has never been so silent before, which I like very much lately.
Better pics coming soon.

Wally
July 24th 2012, 03:23
Well done! Only some transitions are a bit abrupt (not curved), but its a unique design indeed!

Xellex
July 24th 2012, 05:37
yeah, that's because I was a cheap-ass and couldn't convince myself to buy a few more 50mm diameter bends...
I guess you can easily figure out the reason why the collector is oriented to that position, and where I got the inspiration from :P

Xellex
July 24th 2012, 19:19
better pics:
http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6122.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6122.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6125.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6125.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6133.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6133.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6127.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6127.jpg)

http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6131.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6131.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6134.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6134.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6139.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6139.jpg)http://i260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/th_DSCF6137.jpg~original (http://s260.photobucket.com/albums/ii25/xellex_anonim/2012-07-23%20In%20sfarsit%20am%20terminat%20evacuarea/?action=view&current=DSCF6137.jpg)

subamaniac90
January 12th 2013, 08:05
Hello, I am trying to fit projectors on my car, and i saw your project. What is the black thing that you used to move away the glass from the projector? Did you do any other mods on your fender? Thanks in advance.http://i260.photobucket.com/albums/ii25/xellex_anonim/2009-07-30%20Faruri%20Xenon%20cu%20lupe/30072009001.jpg~original

Xellex
January 22nd 2013, 21:29
hi, I used some epoxy resin and it's black because I wrapped that part in black masking tape. It's not the greatest solution, and I'm gonna try to remake them when I get some free time.