After a little work, and a little help from a 'Cherry Picker'. I managed to get my body back on my pan, by myself. I rolled it up in the garage and put it up on four jackstands, bolted the lines up and nervously checked the fit...

PERFECT! well, not 100% but concidering I made the water lines fit the pan and not the pan and the body. The're great. I thought they'd work out, but I have to admit, I did have my doubts. The passenger side is like I hoped, pretty much a straight shot. But the Driver's side is another story. I think I might up having to use a bleeder similar to Volkdent's.

In the last two pictures, I have a little clearance issue. Then again, it could be a lot worse. It could have hit the body. ;)

Comments are always welcome.
Thanks...

Will the driver's side line clear the fuel tank?

Rich

This is just great! Keep the updates coming. I hope by the time I get that far in my project, I will remember to refer to all these good posts. VERY usefull info to be had here(although I will not go H2O, this is STILL usefull info to me)...

Keep on 'chopping away', and post as you get along :agree:

Why hadden't you let some bends maked? (less restrition for the water)

Wiebrand

Thanks guys.

Rich, I'm not sure if it'll clear the tank, if it's too tall I can cut it down, but at least it's not short. :)

Wiebrand, I believe you're asking. Why didn't I just bend the tube? I coudn't find a tubing bender anywhere around to rent or barrow, and buying a bender just for that seemed too much to me.

Mikey,

I've been having the same dilemma over the purchase of the tube bender until I saw a link here for blind chicken racing. :eek: If you check out their web site in the tools section, there is a section for a home built tube bender and a couple of others that people have built. :agree:

To say the least, it looks promising and I am planning to build one to test it out. I was going to use it for the custom exhaust system for the Ghia, but I have since order a A1 Sidewinder for the Ghia instead. (Should have it in a week or so) :)

Anyway, it might be worth a look. I have a buddy who works in a sheet metal shop who may be able to CNC Plasma cut me out the components after I CAD the thing up. I'll post some photos of the work. It might not be till the fall though, as I have to get rolling getting the garage set up before I start making tools to fill it up. ;)

Cheers,


Doug

I bought some plans similar to BCR's bender to make my own a while back, but the dies are expensive. At least from what I've seen. He said something like $300-325 in the bender. I bet it's mostly in the die, and jack.

I've also seen a few cheap benders on ebay. But I wasn't sure if they'd work for a cage or something. Since they don't have the right size die. I was thinking 1-5/8" x .134 tubing for a small cage. Seats back and maybe a pair of low door bars. I don't want to fall on them getting in and out everytime. :rolleyes:

Yep Mike, that's what I asked. There are companies that can do that against an relatively nice price (in Holland I know a couple).

WIebrand

Mikey,

My research says the exact same thing about the cost of the dies, somewhere in the $350 to $400 range, depending upon the size of the dies. There were a couple of suppliers I found on the net listing the dies separately.

One company also had a manual tube bender for around $375 (I can find the link if you want). However as soon as you added in the hydraulic option, it jumped to almost $1,000. So as far as that goes, the BCR bender is a deal with the hydraulic bending.

I'll just have to fab a couple cages and exhaust systems for my buddies to offset the cost of the dies. :D

Cheers,


Doug

Hmmm, just a wild guess, but couldn't a muffler shop do that sort of bend?

George

Good question. That was originaly one of my options, But I'd have to have the pan at the muffler shop to get the right angles. If I didn't and it was bent wrong, because I didn't figure the angles right, I'd be stuck. Welding might not have been the best choice. But I thought it was good to work with the tools and skills I have. Still, with 1-1/4" ID tubing, I doubt I'll have a flow problem. If anything it'll be too big.

Mikey, you could use some filler rods or coat hanger and bend to the correct angels. Then take that to the muffler shop ;) . Just my thoughts. Have used this to bend 2in. 304SS tubing at work since we couldn't move the 150,000 lb. machine to the rebuild shop :laugh: .

Hi

Can you buy mandrel bends where you are? Thats what most people down here use to make custom exhaust systems.

Steve

http://www.999automotive.com.au/PICS.../B90250SSP.JPG

Hey Mikey,

Good to see you are moving forward. I haven't done sh!t the last couple months... just couldn't get myself to go into the cold garage.

Pretty impressive to see your accomplishments. Maybe when the weather gets warmer I'll get going again.

Keep up the good work.

Rob.

Danny, that's a good idea. Although I was told by Tim that a muffler shop couldn't make the real tight corners I needed, their corners have a smoother and larger radius.

Steve, I'm not sure about the mandrel bends. I'll have to look into it more once I get to my exhaust. I believe the water lines will work out fine.

Rob, I hear ya. I wouldn't be working out in the garage during the winter if Tim didn't have heat. :laugh: I'd love to see pictures once you get going again.

Thanks for the kind words.

It's A Boy!!
 

YEAH! After almost 2 months and 1 failed deal on ebay. I finaly have my Subaru engine!

I started working on it a little tonight. Took off the intercooler, altenator, power steering pump, and AC compressor. It really started to take shape after a few of the bigger parts were off. I carefully removed all the parts that I'll reuse and the parts I won't. I didn't want to ruin something I might end up needing by ripping stuff off. I also began to more or less get familiar with the Subaru, running down hoses, fuel lines, vacume lines, coolant lines. To get a good feel for the location of everything.

I'm not sure where I'm going to go next. I might pull the intake, along with a few misc. peices, and start fitting it in the car. Then decide to either flip the intake or not, sort out the wireing, air filter/ intercooler, coolant lines, replace timing belt... A bunch of things to get sorted out. But at least I have an engine now. :cool:

I've also enclosed some pictures. It has a long way to go, but I'm definatly going to clean it up.

GO! Mikey! Go! :laugh:

I can't wait to see that going in. Thanks for the update Mikey.

Good stuff Mikey !

Congrats on your new motor !

What motor is that ? a 2.2 ?
Have you decided yet what you are going to do for engine management ?

Rob.

Thanks guys. I'm going to spend this weekend putting it in.

Rob, it's a 2.0 Turbo. EJ20T. I'm going megasquirt with the EDIS ignition. I have the computer and the harness already, I just need to buy up the EDIS stuff.

I might end up making a removeable rear apron, I'm not sure just yet, I do know that rear sheet metal needs replaced. It'll be easier just to replace it, it's pitted and bent like crazy. The flat peice on the back, not where the latch sits. It's terible.

I was looking though your site again last night, Trying to decide to reverse the intake or leave it stock. Stock looks a lot cleaner. but I'd have to cut on the firewall. Although I'm not worried about going back stock with this body anyway. And if I turn it around I'd have to relocate the altenator. :rolleyes: hmm... choices, choices...

hey mikey sorry for this but steve c whered you find that bend thanks. and sorry mikey.

I'd fit the motor first before deciding on how to mount the intake.
Also keep in mind that coolant cross-over. Stock it ends at the rear of the car, which looks kinda akward. (check the earlier motor picks on my site, you see a big black rad hose on one end).
You can flip the manifold, but you will need to reweld the neck since it will hit the bellhousing.

You might need to cut the firewall anyway because of the turbo.

Looking forward to the updates.... I actually spent about an hour on the bug today !! Trying to make up rad hoses.......

Rob.

Bow, it's cool. You could have always PMed him. ;) But seriously, I don't care.

That's about what my plan was, kinda sorta. Just fit the engine then work on the intake location after the engine is in. Since I have more room in the back, compared to a bug. I might like how the intake looks turned around.

As for the manifold, cutting and re-welding won't be any problem for me. :D

I was just looking at the engine just before we left the shop tonight. And I even brought up having to cut the firewall for the turbo. I'll have to cut it, I'm just wanting to make it look like it belongs.

I thought about saying in my last post, "you need to get back after it." :laugh: That's great. I'll drive up there and show you when it's done. Biggest thing left is paint. I mean, the most expensive. I don't have the engine 100% figured out yet. :laugh: But I still have time.

Hi

Theses people have them, http://www.999automotive.com.au but Im sure you could find them on Ebay or in your area. Ive bought them right down to 1 inch OD.

Steve

thanks. sorry i didnt think of pming him

Sweet you finally got the engine. I know on a 914 the intake needs to be swapped around so that you odn't need to cut a hole into the rear trunk area(what would be the firewall on a type 1). There are a few guy doing this conversion over a club914.com maybe that could give you a few good ideas. I can't wait till its on the road.

I have a Subaru in my Ghia!
 

Thanks Nick.

I got my engine in the Ghia!!! (last friday) It's in! I didn't want to post about it till I had good pictures. I took some the day I put it in, but they were Terible. To those that have been following along, you'll notice the better looking pictures are the pictures I took at night.

After making a hole big enough for the engine and clearancing for the turbo. I tried putting it in. I tried pulling it up into the compartment with a cherry picker. What a Beast! After fighting and pulling. I finally just got out the battery operated sawzal and cut my rear apron off. :mad: Not before I put a few good scratches on the two side timing belt covers and having the engine land on my foot, I love my steel toe boots. :rolleyes: After the rear apron was off it just slid into position.

I took a few more parts off. Intake, water manifold, and I started making a bracket for the altenator. I have decided to turn the intake around. I thought about doing something like Martin's (bug@5speed) bug. He took and made a resessed box in the fire wall. Unless you look closely, you can't even tell. But I can't because of the location of the turbo.

Now I'm going to start working out the iginition system, the air filter/intercooler, water lines, exhaust... I'm also going to surround the engine some how so there isn't a big gap all the way around it. It seems for every 1 thing I accomplish there are 5 more things I need to do. :laugh: I knew when I decided to go Subaru. There would be a lot of work, and I knew it would be more than I aticipated. It's not just the Subaru conversion. For example, I put my engine in, and now I need to give some more attention to the rear suspension. The rear wheels stuck out past the wheel arcs. That wasn't a problem till I added weight to the back, now they rub. It will be running and driving before paint. So I need to put money into the brakes... It doesn't end. I just need to stay focused and keep in the mind set of just tackleing this car one thing at a time.

Ah, felt good to vent a little.

Comments are always welcome, but please don't correct my spelling.

Good job Mikey! :agree:

Now if I understand you correctly, you didn't want to butcher the firewall so you will be turning the intake manifold around correct? Does it bolt up in reverse of normal?

Are you making a bracket for the alternator because of your reversal (or plan to) of the intake manifold?

What could have been done to avoid cutting the rear apron off? (as if I'm concerned about originality here :D )

Thanks for keeping me motivated.

Kevin

nice progress Mikey :agree:

Thanks Vujade.

Kevin, yes I'm flipping the intake around backwards. And yes it will bolt up backwards. It's sitting backwards in the pictures.

Yeah, I started making the original alternator bracket work, It'll support the alternator now and piviot, But I need a sloted peice so I can adjust the tension on the alternator belt.

To avoid cutting the rear apron off? Lift the whole rear of the car up, then put the engine and tranny together. Then lower the body back down, but you better hope you never need to get the engine out of your finished car. I'm serious, I can't see no other way. I didn't want to keep removing material off the rear apron other wise I'd have a big gap. Think about it, once a bug engine is in, you have a big gap bettween the crank pully and the apron, but in the stock engine you have sheet metal to fill that gap. With a Subaru you won't, unless you make something. But you can't forget about the deck lid latch that sits on the apron too.

Make sence?

Thanks. I like motivating people. Helps keep me motivated too. :laugh: :D

Mikey,
This awsome, I am really enjoying reading about your and Yetibone's projects. Thanks for all the posts, photos and other info, keep it coming.

SWEET! I would use some zeus fasteners to reattach the rear apron. You don't need to seal the engine compartment because it's water cooled now. :D

sweet so when you gonna start her

Thanks Nigel. I'm glad you're following along. :)

Thanks Nick, I don't need to seal the engine compartment because of function, as you mentioned, it's not aircooled. I wanted to add something around the engine for looks alone.

Bow, When will I start her? Hmmm, I still need a few parts for my EDIS ignition system. I found a website that sells the used parts, but I'm sure I can get the parts cheaper by going to a junk yard myself. After I gather the parts, I'll need to wire it all up. Then figure out all the vacume lines and fuel lines. I'm in no rush, although I'd love to hear it rumble to life. :laugh:

Nothing major to report. On April 28th I had my wisdom teeth taken out. :( So I didn't work at all that weekend, and this past weekend I did some but only little. I'm still trying to get back up to 100% after the wisdom teeth.

I started making a cover for the turbo where it sticks though the firewall. I ended up using the bottom of a old rusted out gas tank, nice curves. I also clearanced some more for the turbo.

My biggest thing this past weekend was making a list of all the things I need to do on the body/chassis. Before I start trying to add more things. Rear apron, holes to fill, finish welding my dash, clearance the frame horn for the clutch arm... the list goes on, I couldn't figure out where to start. There are so many places that need attention. :laugh:

I also have some good news. I just completed my 2nd year at college for welding. And I have recieved my Entry Level 1 welding certificate from the American Welding Society. :D I may or may not take welding classes this august to go for my Level 2. That depends if my teacher has the room in his classes for it, but if he does, I'm sure I will. I'm trying right now to get on at a local place called Titan Fab. I'm sure that'll make a good summer job to help build money up for the Ghia.

I almost forgot, Pictures?? I have some Energizer rechargeables, but I can't find the charger. :rolleyes:

Keep chipping away at it Mikey. It will come together.

My humble beginings. :laugh: Updates soon...
http://i73.photobucket.com/albums/i2...e.jpg~original
I also have a Photobucket account, so I can post pictures like this. :D

Update!
 

I have an update. It took me a little longer than expected. Life gets in the way sometimes.

First I tried drop spindles with a standard beam. Pushed the wheels out and wasn't really low enough. Even though I had no weight in it. So I tried a 2inch narrowed beam with adjusters and drop spindles. I could get the perfect hight, but the steering radius was a joke. I had almost none. I had to do something else. Awhile back I found a guy named John Kelly. He made weld on flares for the Ghia. Nice looking flares, but a lot of cheddar. (money) Almost $1,200! Fat Cheddar! When I found a dvd he made, I didn't think I could do it. But I'm out of options. So I bought the dvd. I love it. I just wish he did more on the Ghia. His method is to stretch the metal. I'm hoping to widden the front by at least an inch and a half. That would be a lot better for turning radius. I put the stock beam back in it with stock spindles. The drop are going to be machined for the 993 brakes. Here are a few pictures of what little work I've done on it. I've already bought a palm nailer, the hammer is killing my arm already. And I have a few more tools (toys) coming to help with the fender shapeing. Right now it measures about 1/2-3/4inch widder than it was when I started. I made marks to I measure the same spot each time. The only major snag I've run into is the friggin' seam in both fenders. I hate it. There is no way around it. I can just TRY to work with it. They did a terrible job. In about 10 minutes I beat out most of the low spots they just filled with putty. I'm using a leather bag full of sand and a ballpen hammer, then a hammer and dolly to flatten out the bumps in the metal. I already know the fender will have some putty in it, but there isn't much I can do especialy around that seam. I thought about welding a new fender on it. But after I get over the heart attack of the cost. It would be a ton of work. Not sure if it would really be worth it. I'll just keep my seams and work with them.

http://i73.photobucket.com/albums/i2...1.jpg~original
http://i73.photobucket.com/albums/i2...2.jpg~original
http://i73.photobucket.com/albums/i2...3.jpg~original

The rear is a whole differant story. It's not even the same book. I'm going to have to do some major head scratching on that one. The problem isn't the fender really, it's the inner fender. I have to almost cut it all out. Work out the fender like I'm doing the front, and put the inner fender back in. It's going to be some crazy fab. And I'll be lucky if I make it look like anything. If I had a set of 9"s I'd just take a peice of 3/8" square stock and make a new wheel opening with that, then lay a peice of new sheet metal on that to make the fender. Then shape it like I'm shaping the front. Then I can widden the fender any amount. With either metod I'll have to do some crazy work with the inner fender. The cost of a Ghia I guess.

I did some other work before the fenders. I realized a while back that the cost of sun visors for a '64 and earlier are crazy money. They attach to the rear view mirror. Over $100. Way too much. So I just bought some visors for a '65 and newer I decided to just make those fit. Luckily Tim had a roof clip, for what ever reason I have no clue, off a '68 or '69 Ghia he use to own. With all the metal work I've been doing on Tim's '47 I decided I'd section in the header peice for the sun visors. Just cut the old peice out and cut the new peice long. Then trim it to fit. And it'll be covered by headliner. So it won't be obvious. See picture below... I didn't realize it until I got home and downloaded it off my camera but it didn't turn out so good. I should have used the flash. But trust me, that header has been replaced.

And I replaced the original battery tray in the engine compartment. It was just a big hole. My first body man, what a joke, cut it out with intentions of replacing the metal. See picture below...

On a personal note: I won't be making any more trips to the great white north. My girlfriend and I broke up. Oh well, now I can go crazy on my vw. I don't like the fact I won't get to meet up with Lanner again and maybe some of the BAG guys.

Comments? Questions? About the project. Always glad to recieve either or both.

Mikey, why don't you just make your own flares to weld on? I'm sure you've seen what ccain is doing in the paint and body section. Get out the cardboard and start cuttin' patterns to try. Then go to town with the metal (insert slipknot into CD player here) You can do it:D

I saw those. Very good work, just not for me. I'd rather try something like this, here is John Kelly's website so you can get an idea of the shape I'm going for http://www.ghiaspecialties.com/

This is a link right to the Ghia pictures.
http://allshops.org/cgi-bin/communit...=9980109614663
They're a little more subtle than the lip flare ccain is doing. Also, I really don't want to change the shape of the rear fender opening. I want to leave it like it is. It's not pefectly round.

There is something that needs adding to Tim's shop. A cd player. He only has a Radio/casset/record player. :laugh: I'm surprised it doesn't have an 8-track on it. I just listen to the radio. He said I can add a updated radio, I just don't have one.