915 install

[wrenchnride247]

Well, since the forums are back up I can post some progress with tranny install. I got some parts from bug@5speed, but didn't get the transverse mount, because, looking at the mounting points it would not work with the 944 sway bar i'm going to use. So, I got some volvo 240 motor mounts, and some metal I had lying around and came up with this.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4341.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_4343.jpg~original

Now I have to make some mounts for the sway bar right around the area bug@5speed's transverse would go. (sorry Martin, your parts are still awsome though) You can see in the pic below the position of bar.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4345.jpg~original

And a shot of car rightside-up!

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4347.jpg~original

[ricola]

Nice job on the front mount, my G50 mount ended up a bit further forwards still than that so I'll still have plenty of room for the anti roll bar too, although I want to get a bit of bracing across my new framehorns too if possible...

Rich

[Wally]

Nice fabrication! I am still unsure if my White-line rear sway bar will fit again (haven't tried it yet), but the possible use of my old modded 915 bracket was the reason I gave priority to that.
Cool that you can flip you car to measure and do the mods!

[wrenchnride247]

Thank's guy's. I hope this will work OK. If not, I will make another cross member that uses porsche mounts. ;)

[petevw]

Nice setup!

Have a pic of the entire stand?

[jmd]

nice mounts, love the install.
I would like to see more of the details for the section where you seem to have built "Stands" that your volvo blocks are mounted.

[wrenchnride247]

Nice setup!

Have a pic of the entire stand?

The rotisserie is rated for 4000lbs. I added a extra attachment point for a 3 in. 3/16th thick square tube that has three cross bars that attach to the outer edge of pan where it bolts to body (used exsiting mounting bolts for pan) I can spin the whole car 360 deg. with one hand when I have it raised to the top of stand!

These are some pix from last year, but here you go Pete...

http://i52.photobucket.com/albums/g38/wrenchnride247/100_2892.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_3892.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_3893.jpg~original

[wrenchnride247]

nice mounts, love the install.
I would like to see more of the details for the section where you seem to have built "Stands" that your volvo blocks are mounted.

I used the left over 3in. tubing from rotisserie addition, cut some angles from that, and welded them to the torsion housing locating off the pivot mounts for IRS. I didn't take pix of every step. You should be able to see them in one of those pix.

[Sandeep]

Now that is sweet ! Great fab skills on the 915 installation.

Sandeep

[wrenchnride247]

Thank's Sandeep. I've been waiting to post this stuff here. A big thank's to getting the forums back up. ;)

[NO_H2O]

Wrenchnride has got the skills alright. He can cut it, bend it, shape it and he can weld the crack of dawn. Mad Welding Skills.

[dub_crazee]

very nice install - did you use the bug@ rear cradle? how does it attach to the gearbox/bell housing area?

[wrenchnride247]

very nice install - did you use the bug@ rear cradle? how does it attach to the gearbox/bell housing area?


Yes, I have a bug@5speed rear cradle. It comes with aluminum blocks shaped to fit the 915 bell housing. The blocks are bolted to cradle with four rubber mounts. You will have to drill holes through blocks and bell housing. Then, you must also use "flat head" hardware so it dosen't hit flywheel.

[wrenchnride247]

I thought some pix of the Bug@5fivespeed parts I used might be helpful.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_1500.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_1497.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_1502.jpg~original

The rest of the tranny rebuild was done by Carquip. They are top notch (but not cheap) Very happy with their services and support. They also added something very nice to my gearbox... can we say TRACTION!!!!

http://i52.photobucket.com/albums/g38/wrenchnride247/IMGP1912.jpg~original

[chug_A_bug]

They also added something very nice to my gearbox... can we say TRACTION!!!!

http://i52.photobucket.com/albums/g38/wrenchnride247/IMGP1912.jpg~original[/QUOTE]


WOW Just Keep it out and Mount it as a trouphy :D
that's One Sexy peace...


Chris.

[Wally]

Wow! :eek: a Paul Guard (GT) diff! That is a torque biassing diff right? Never seen one of those from him, but whatever comes from Guard Transmissions is absolutely top notch!

Very, very weel chosen. Pity they cost so much as I would love to have a TBD for the G50.
Well, there must be s/th to be wishfull for ;)

What made you decide for the TBD over a LSD?

[wrenchnride247]

Thank's guys. Wally, Carquip only sells GT products. I asked about getting a Quaife TBD, and they said they were a little too "industrial" for their standards :rolleyes: The GT LSD was more than the TBD so I did get the cheap one ;)

I can't wait to drive it!

[Clatter]

I did get the cheap one

OK, It's killing me.. Got to have something to dream about...
(Don't you hate it when people ask this question)?

How much did that Bad Kid set you back??

[wrenchnride247]

$1495 US for just the diff.

[wrenchnride247]

Got some time to make the 915 shift rod work for my install with a 915 shifter. Only had to cut the rod, flip one end around for more angle, and add a 7" piece of 1" tubing.

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod01.jpg~original

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod02.jpg~original

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod04.jpg~original

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod05.jpg~original

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod06.jpg~original

[wrenchnride247]

I also cut 1" off the end of the selector rod on the tranny to give more clearance in the tunnel. The shaft is hardened so had to use solid carbide bit to drill new set screw hole.

http://i52.photobucket.com/albums/g38/wrenchnride247/shiftrod03.jpg~original

[chug_A_bug]

love your Work dude...:thumbup:

Chris.

[wrenchnride247]

OK. I changed my mind on using the Volvo mounts. I didn't want the nose of my trans just supported by rubber. I could have redone the mounts to make it work, but went another route. I like this set-up better. I MIG welded this stuff. These are urethane bushings from Summit racing. This deal will hold up better I think.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4805.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_4806.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_4807.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_4808.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_4809.jpg~original

[evilC]

I like all the work but did you consider the ground clearance?

Clive

[wrenchnride247]

I like all the work but did you consider the ground clearance?

Clive

Yes, ground clearance was measured when car was still together Clive. The rear sway-bar, and header system sit about the same level. It just looks like it sits real low. The volvo mounts sat even lower than this. If I'm not happy with it when the car is put back together for final mock-up I will change it...no big deal for me (I've got a 911 crossmember to cut-up too) just trying something different. Thanks for the comment's though.:)

[Wally]

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4347.jpg~original

I had the same thoughts as Clive when you showed the last pics:very nice work, but how low?
It looked like your trans sits lower than mine sat. The above pic I copied from your first post suggests this also: the gearbox flanges are pretty low, like when you would put a CV onto them, they would hit the forks...
Could be optical illusion though...
My 100mm CV's on the 915 sat VERY close to the forks and stil it looked like I had more ground clearence.
Just thinking out loud with you here and hoping to give you some reference ;)

[wrenchnride247]

I had the same thoughts as Clive when you showed the last pics:very nice work, but how low?
It looked like your trans sits lower than mine sat. The above pic I copied from your first post suggests this also: the gearbox flanges are pretty low, like when you would put a CV onto them, they would hit the forks...
Could be optical illusion though...
My 100mm CV's on the 915 sat VERY close to the forks and stil it looked like I had more ground clearence.
Just thinking out loud with you here and hoping to give you some reference ;)

Wally, The mounting position was set by Martin Bott's engine support. If it set any higher I couldn't close my deck lid. The camera angle may be the problem. I have 944 flanges on the trans. I could of easily took a hammer to the frame horns to make clearance for CV's, but what fun would that be :rolleyes:

[wrenchnride247]

OK people. I just took some more pix, at a better angle, so you can see it doesn't sit any lower than the bottom of the lowest point on the trans case. I hope this helps. (I was looking at the pix and thought it looked low too after Clive posted)

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4810.jpg~original

http://i52.photobucket.com/albums/g38/wrenchnride247/100_4812.jpg~original

[Wally]

Good angle as it is indeed not any lower than the tranny rib. No worries then ;)

[wrenchnride247]

Wow, I even feel better about it now. I should have posted a better angle the first time :o Metal fabricators make lousy photographers! :lmao:

[evilC]

And I thought I was looking at it upside down!:lmao::lmao:

Clive

[dub_crazee]

lovin your fabrication skills dude :) mount looks proper sturdy!


i was thinking about the rear cradle but did wonder about clearence issues with the flywheel. if using countersunk bolts ( i gues thats what u mean by flat headed hardwear?) i was concerned about the thickness of the bell housing where it would be bolted through? what are your thoughts on this?

loving your work

Deano

[wrenchnride247]

lovin your fabrication skills dude :) mount looks proper sturdy!


i was thinking about the rear cradle but did wonder about clearence issues with the flywheel. if using countersunk bolts ( i gues thats what u mean by flat headed hardwear?) i was concerned about the thickness of the bell housing where it would be bolted through? what are your thoughts on this?

loving your work

Deano

Thank you for the compliments. The "countersunk" bolts are the recommendation of Martin (bugat5speed) these are the only bolts that will clear the ring gear. The bellhousing is very thick, and should not be an issue.

[wrenchnride247]

OK. Sort of an update (no pix :() After pulling the trans in and out several times (another part of this post) with this new front crossmember...I'm going to change it AGAIN :banghead: it makes it really hard to drop the trans out. So, plan C is taking shape. Right now I'm reworking the bottom of the chassis where the shift coupler and rod mate (Which is what got me thinking about the crossmember) it will be water tight, and use some more porsche parts. ;) Work and the holiday coming up will keep me from having it complete for at least a week or more...

[jmd]

can you tell me what type of spring plate covers your using? I was re-reading this thread and noticed they are pretty clean looking.

Great work on that new mount, I myself am creating a new custom solution as I have not had much luck with the bug@5spd guys being any sort of responsive... oh well, I can fab up my own stuff.


thanks for continuing to share you build progress.

[wrenchnride247]

The covers are 944's with some machine work done to them ;)

I'm busy with other people's problems (again) so, mine is sitting (again) :mad:

I had no problems with Martin and Alex...

[wrenchnride247]

OK. This should be the last mount bar (I think) The mounting pads on the pan were for these from the start, but wanted to try other mounts just to be different. The boot is from the 911 the trans came out of, and seemed like a good way to keep water out of the tunnel. So, had to put the fab skill's to work again on a "box" for the shift rod and linkage to come through. No getting in the back of the car anymore to remove the shift rod coupling!

http://i52.photobucket.com/albums/g38/wrenchnride247/100_5012.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_5013.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_5014.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_5015.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_5017.jpg~original

[Wally]

That is absolutely SUPER how you made that shift rod entry box and seal!!
Never seen it before, but should be the standard from now on :)

I should have done s/th simularly...

[ricola]

Now we're talking! That's superb... From looking at it the only improvement I can think of is to extend the fillet pieces from the trans mounting plate further up the bar to better resist twisting. I've just finished painting my pan but you are making me consider changing it already!!!

http://www.ricola.co.uk/images/cabrio/chassis_paint_1.jpg http://www.ricola.co.uk/images/cabrio/trans_tunnel_close.jpg

[NO_H2O]

That came out sweet. Great idea to use a bus boot. Looks very clean.

[dub_crazee]

superb!!!

[NO_H2O]

Ohpps. Looked like the bus boot but I should have read the text. It's a 911 boot. But it is still a great looking system. Danny is a fab master.

[wrenchnride247]

Now for the next part...getting the new clutch parts installed :D

http://i52.photobucket.com/albums/g38/wrenchnride247/100_5019.jpg~original

[wrenchnride247]

Didn't get as much done today as would liked, but still moving forward. I have the new sheet metal fitted, and tacked. Looks like 14ga. metal is a close match to the original thickness. Will drill the master cylinder mounting holes, and finish welding tomorrow after work.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_5021.jpg~original

[ricola]

I'm sure you haven't but don't forget the crush tubes... Nice to see it done with the side piece at an angle, most others I've seen do it vertically, must be a pain for the body seal!

[wrenchnride247]

I'm sure you haven't but don't forget the crush tubes... Nice to see it done with the side piece at an angle, most others I've seen do it vertically, must be a pain for the body seal!

Quit rushing me...I do have 1/2" dia. SS tubing for crush tubes ;)

Getting a good seal on the pan gasket is one reason for the angle. This is about the best you can get given the distance from point A to point B :D

I was hoping to post the finished mounting, but didn't have a 1 5/8" hole saw :mad: for the boot, and rod to go through (got 1 1/2", and 1 3/4" hole saw though :rolleyes: ) Guess I'll bring one home from work tomorrow...

[wrenchnride247]

OK. I brought home a hole saw, and finished the mounting holes. Next is matching what I did here to the firewall on the body. I need to get the pan back on the body to put mock-up motor back in for building a header. Because, coming up real soon, I get to build my motor, and dyno it, but i can't do that without a header. So, pedals and slave cylinder mounting has to wait.

http://i52.photobucket.com/albums/g38/wrenchnride247/100_5022.jpg~original
http://i52.photobucket.com/albums/g38/wrenchnride247/100_5023.jpg~original

[jmd]

man that shift linkage solution is awesome. i have been inspired in my own solution. thanks for blazing new paths!

[wrenchnride247]

Thanx man. I thought all the people thinking about doing (or have done) a 901, 915, or G50 would like this idea...it's just taken ALOT longer to get to do it, because of everything else that gets thrown my way for help.

[dub_crazee]

i agree with the above dude- its a great solution - im hoping to do something similar in the coming few weeks

out of interest how are you going to be mounting your clutch slave cylinder to the clutch lever arm?

[wrenchnride247]

i agree with the above dude- its a great solution - im hoping to do something similar in the coming few weeks

out of interest how are you going to be mounting your clutch slave cylinder to the clutch lever arm?

I haven't had time the last month or so to get back on my project. In the coming weeks I will have time again, and will do that part of the conversion. It will be easier to show pix of it then to explain it in words though. ;)

[dub_crazee]

haha no worries - you sound very busy!

il be jumping back on my chassis this week too - finish getting the gearbox mounted and the tunnel mods done - fit fuel lines and 5 bar kafer set up in! busy busy!

[wrenchnride247]

Well, I just finished my friends motor rebuild and he will pick it up tomorrow afternoon :) Then, I can get back to the important stuff :D . This weekend is the first VW event I attend every year (SEVWA Dyno day sat. and, show/drag on sun.) so, will not make any head way this weekend, but I may find a few more parts for the project though :)

[Xellex]

any news on this? I'm right behind you with the 915 install, and your topic, amongst a few others here are always inspiration to me!

[wrenchnride247]

No progress on this part of the build. Got my motor built, and switched back to making my header so I can dyno it. This past year has not allowed alot of time for my (VW) projects. :(