Starting on some suspension goodies. Custom lower control arms are next.
I happen to stumble across these turbine shafts in the machine shop that suited my needs:D Material is 4140 and so it will be plenty strong enough and then coupled to that is a 5/8" Chromoly Heim Joint.
http://i7.photobucket.com/albums/y25...4.jpg~original

http://i7.photobucket.com/albums/y25...8.jpg~original
Installed some of these 2psi residual pressure vavles. The brake pedal has the feel I was looking for and I now have the some confidence in my brakes.
The brake system now consists of:
-Stock master cylinder
-All new steel brakes lines
-Stainless braded flex lines
-Wilwood proportioning valve(installed on the rear circuit)
-1983 NA Porsche 944 front and rear calipers
-K sport Hydraulic Handbrake
-Empi 2psi residual pressure valve

If you are like most of us you will find yourself modifying this one also in no time!:D

http://i7.photobucket.com/albums/y25...3.jpg~original
Sneak Peek at custom lower control arms. This is the inner. Outer will also be heim joint with a roll centre correction spacer for the spindle. Also need to figure something out for the sway bar attachment. These will be a bolt on unit.:)

when you get these done, id love to be interested in a set.

http://i7.photobucket.com/albums/y25...0.jpg~original
Cleaned up my trailing arms and made some new lower coilover bushings.
Im using a 1/2" precision ground shoulder bolts so this will get rid of some of the slop I was having. Also was looking into the rear coilovers I have and turns out they are Koni's:cool: over $500 a piece:shocked: . Next up I am ripping out the stock diff and putting in a spool:eek:
http://i7.photobucket.com/albums/y25...1.jpg~original
Also while putting in the spool Im upgrading to Type2 CV joints and axles.

Can't wait to see the front control arm setup.

...oh and I should probably wing some springs down to you, eh?

-Dave

Hey Dave. Yeah that would be good to get the springs back. Bring them along with the rally beetle if possible:D. Also Dave I lost your phone number when I updated my phone. Mind sending that over again. I might need some pointers on setting up the new diff.

Thanks

604 849 0076 - Shoot me a txt as I'm not sure I have your number on my new Blackberry.

-Dave

After some clutch chatter issues and wanting to keep things in place better I'm switching to solid mounts. I'm also going to reverse the rear cradle and mount the gearbox forward a few inches. Ditching the front rubber mount and going with a mid mount. I'm going to get rid of the urethane piece that the midmount came with and use aluminum and drilling through the frame horns to secure it.
http://i7.photobucket.com/albums/y25...2.jpg~original

http://i7.photobucket.com/albums/y25...2.jpg~original
Flipped the rear cradle and mocked up the gear box. Going to make a solid front mount and also use a mid mount. Pulled my shift rod and found out it was bent. So I ordered up an adjustable end and am going to shorten it by 2". Also started setting up the spool differential. I installed my original ring gear and torqued it down. Then plopped it in the gear box. It seemed too tight after installing the diff cover so I removed a shim out of it. Now it seems pretty good. I measured .015" of play while rotating the diff using this method however I am a little unsure of it as this is the first time I have setup a rear end. Factory settings from the manual say .006"-.010". Any pointers?
http://i7.photobucket.com/albums/y25...9.jpg~original

http://i7.photobucket.com/albums/y25...3.jpg~original
Gearbox is ready to go. Bearing preload and backlash are set on the spool.
http://i7.photobucket.com/albums/y25...4.jpg~original
I "deconstructed" my OEM front mount and found the date of manufacture was cast into the piece:shocked:. I am going to mill down the face and resuse this piece as a solid front mount.

http://i7.photobucket.com/albums/y25...8.jpg~original
Solid front mount.
http://i7.photobucket.com/albums/y25...2.jpg~original
Shortened and adjustable shift rod made with slightly heavier wall tubing than OEM.

http://i7.photobucket.com/albums/y25...6.jpg~original
Moved out of the city and into the countryside. No more neighbours complaining about "engines revving" and such. Built a workbench and organized the garage a bit.
http://i7.photobucket.com/albums/y25...2.jpg~original
Added an GM Intake Air Temp Sensor. Going to see how effective the NACA ducts in the window routed to the intercooler are. The solid mounted engine and gearbox aren't as bad as I thought. Everywhere on the internet said it would rattle my fillings and shake bolts loose but I like it. Less wheel hop more rocking of the engine. Now to take advantage of the country roads around my place. Ft. Langley has some awesome twisties:D

I'm interested in the results of the NACA duct test.

x2

http://i7.photobucket.com/albums/y25...1.jpg~original
Did a string alignment to get the car in ballpark alignment.
http://i7.photobucket.com/albums/y25...1.jpg~original
Was going to install this accusump but stripped a brass ball valve so need get a new one of those,:angry:
http://i7.photobucket.com/albums/y25...3.jpg~original
Went for a few "drives" around the neighbourhood this weekend. Did some logging. Was only making 8psi of boost but wanted to make sure the AFR's
were in check. I will turn up the boost next weekend:D Intake temperature started out at 14degC and rose to 35degc after 7 minutes of driving. I guess I'm going to have to drive longer to see what the NACA ducts can do for me. Lots of wheelspin too in the wet. Donuts and going sideways are alot of fun with the spool in the rear end.
http://i7.photobucket.com/albums/y25...8.jpg~original
Also finally got this bad boy together. A VF34 ball bearing turbo from JDM STI's.
These little ball bearing units are very tricky to put together especially when you
dont take them apart. Lucky for me I found one disassembled in a box. This is one of the best "bolt on" turbos you can get for the EJ20, very responsive.

i got 2 questions for ya.

1: well i need motor mounts in my 1303 as well. i cant decide on what route to go,how are the solid mounts on the street? do they vibrate the car super bad? ive been thinking about getting some solid mounts.

2: how is the spool diff on the street? does one wheel make noise when turning tight turns? i know in your case its not a big deal as i know your wanting to drift with it. but i had to ask. lol

looking awesome as usual. ill be getting my turbo on my WBX soon, your car is a great inspiration. keep up the good work.

Good to see it out on the street.

http://i7.photobucket.com/albums/y25...9.jpg~original
So here you can see the stock reverse light switch and an M18 Plug I got to block off the reverse light portion of my gearbox when I was moving it forward 2". Turns out the 3mm longer in length was causing me a real headache trying to get the car into reverse. It would move back a few feet then start grinding. Ahh!! I had no idea what to do so I contacted Bruce Tweedle who knows his stuff when it comes to gears and he had heard of a problem like this when someone forgot to install a washer on the reverse light switch.
http://i7.photobucket.com/albums/y25...0.jpg~original
You can see on the top of the plug I installed that there is some wear in that area. So I was confindent when making a new plug using the orginal plug that it would solve the problem. Turns out it did! I would have had no clue and probably tossed the gearbox. So I am pretty stoked that this problem was cured quite easily. Let this be a heads up for anyone moving there gearbox forward that this plug can be no longer the OE one.

Put a permit on the beetle and drove to work today. This happened...:Dhttps://www.youtube.com/watch?v=mJ9emhSuutM

thats awesome. good to see it running solid.

Good to see it on the road.

Modified by steering knuckles for for steering angle. I cut 25mm out of the Porsche 944 knuckles and drilled and reamed a 5/8" hole in them. I noticed with my BMW steering rack it requied alot of input to turn the car. Shortening the steering arm will give quicker response and allow for more steering angle. Before doing this the wheels would point about 35 degrees now the wheel will go almost 50 degrees. I will need to "massage" the inner fenders to make room for all of this steering lock.
http://i7.photobucket.com/albums/y25...3.jpg~original
Stock knuckle.
http://i7.photobucket.com/albums/y25...4.jpg~original
Modified knuckle.

Finally finished my tubular front control arms.
http://i7.photobucket.com/albums/y25...6.jpg~original
Stock vs. Prototype Tubular

This version allows for 25mm roll centre correction. Made in Chromoly.
Length is adjustable from 0-+50mm wider than stock.
3/4" Chromoly Heim joints at both ends.

http://i7.photobucket.com/albums/y25...c.jpg~original

More front suspension goodies.

http://i7.photobucket.com/albums/y25...0.jpg~original

Very Sick.

Any chance you're coming to the Van-Area swap meet tomorrow morning?

-Dave

Hey Dave,

Is that the one at langley events centre?

Nuts. Sorry I didn't see your reply. Today in Surrey, 10 am. Just search Vancouver CL for VW Porsche swap and you'll find my post. 604 902 1595 if you need to call / text me.

-Dave

I totally agree with this. It's absolutely amazing what people can do/build. I'm in total awe - this build is bad a$$..

So I think it is due time for an update.
http://i7.photobucket.com/albums/y25...2.jpg~original
Drove the car to work. Alongside my friends RB26 powered 240z:cool:

Trailered the car out to a drift event in aggassiz on a tight 1/4 mile oval.
Not really the best track to "test out" the car. This happened.
http://i7.photobucket.com/albums/y25...7.jpg~original
http://i7.photobucket.com/albums/y25...e.jpg~original
Great bunch of guys helped me get off the track and back onto the trailer.
http://i7.photobucket.com/albums/y25...8.jpg~original
Moved again:rolleyes:Been busy in the shed rebuilding.
Finally got it up and running yesterday.
http://i7.photobucket.com/albums/y25...f.jpg~original
http://i7.photobucket.com/albums/y25...5.jpg~original
Front end is now fully tubed. Fuel cell added. Changed my front suspension to an a-arm style. It sure is fun to drive around like this. Wife is pregnant so this will be put on hold for a little while. Hopefully will be getting a bigger shop soon so I can fit the body overtop. I purchased a 1 piece fiberglass front end from MarkVFiberglass to replace the damaged section from the crash. I was pretty defeated after "incident" at the track. However I didn't give up just yet. I will add some more details later of what I did with the front end.

Nuts!!! Well when you play like that it was bound to happen, hopefully you got a little feel for it before your shunt. That church reminds me of one on 16th ave? Been years since I've driven in BC but your pictures often remind me of places I've been by.

Jason

naca ducts
 

Hi, I see you have NACA ducts, I glued one to some tempered side glass, I'd like to know how much louder it's the interior noise.

Put some lights on the beast. Next thing is a licence plate:eek:

http://i7.photobucket.com/albums/y25...8.jpg~original

http://i7.photobucket.com/albums/y25...7.jpg~original

Very cool!
We would be good friends in real life :D

Went out to the GCVWS which was held at Concorde Pacific(where Molson Indy used to be). Awesome location and weather made for a great event. Met a couple of the forum guys(Panel and owdlvr).:)
http://i7.photobucket.com/albums/y25...3.jpg~original
Unloading. Had to take the wheels off the trailer to get low enough:lmao:
http://i7.photobucket.com/albums/y25...8.jpg~original
Rolling in.
http://i7.photobucket.com/albums/y25...e.jpg~original
Look who parks next to me:eekno:. Beautiful 993 on BBS LM wheels.
http://i7.photobucket.com/albums/y25...4.jpg~original
Cool Cityscape with Skytrain in the background.
http://i7.photobucket.com/albums/y25...f.jpg~original

Beautiful spot for an event and it looks like the weather was perfect too!

Jason

https://www.facebook.com/photo.php?v=10153256277160354

Put the "beetle" on the rollers. Made 240hp/230tq @ 14psi.

https://scontent-a-sea.xx.fbcdn.net/...16820326_n.jpg

Tips the scales at 1570lbs. With a 40/60 weight split.

for those without facebook and better quality.

http://www.youtube.com/watch?v=o2YOr4IdJhc:)

Went for a little cruise today:)

https://vimeo.com/80524165



http://i7.photobucket.com/albums/y25...2.jpg~original

righteous video man:)