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-   -   Bugaru Project (https://www.germanlook.net/forums/showthread.php?t=9290)

Jim December 16th 2009 09:39

Update...........

after looooong time in hybernation and some engine problems the time has come for me to proceed!

I new i was having an oil leak when i first bought the engine and first run it but this doesnt bother me to join drives and adding oil.....but.....in the truck the mistakes were payed and payed heavily.
After of 15 minutes pushing the bugaru hard in the corners i've heard a noice tickling from inside the engine deck:eek::eek::eek:
I check the oil and found that more than one ltr missing:(:(
A raf estimation was that one of the set of bearings inside the connecting rod was scratched but the engine must be open first!

I stop over and took the car back to home until i get ready for rebuilding
and here we are..

The problem is concerning the bearing inside the connecting rod and nothing more:cool:, so we choose to change some of the engine component parts and rebuild it such as:

New oil pump
New set of bearings
New gaskets kit
New piston rings and more...

Expected to be ready by the end of the month here are some photos in random

http://img24.imageshack.us/img24/4666/image239e.jpg
http://img188.imageshack.us/img188/6...cture004wv.jpg
http://img268.imageshack.us/img268/2...cture007ne.jpg
http://img522.imageshack.us/img522/774/picture009ab.jpg
http://img52.imageshack.us/img52/5589/picture011u.jpg
http://img52.imageshack.us/img52/5993/picture008n.jpg
http://img522.imageshack.us/img522/249/picture002hu.jpg
http://img215.imageshack.us/img215/161/picture010l.jpg
http://img522.imageshack.us/img522/603/picture016ib.jpg
http://img46.imageshack.us/img46/5476/picture020wn.jpg
http://img222.imageshack.us/img222/8...cture006wj.jpg
http://img693.imageshack.us/img693/3162/picture018j.jpg
http://img163.imageshack.us/img163/8338/picture003c.jpg

more to come in next days:D

Jim December 22nd 2009 14:54

Today we got back the block & crankshaft from the machine shop and still waiting for the heads.
Block needs to be cleaned and painted and then will be ready for assembly again.

http://img707.imageshack.us/img707/3996/picture106k.jpg
http://img171.imageshack.us/img171/8968/picture104a.jpg
http://img709.imageshack.us/img709/3189/picture105m.jpg

Meanwhile it was a great opportunity for painting the engine bay.
All the "unessecary" sheet metal were trimmed and after sandpaper the hole surface
it was ready for applying the primer and then painting to metallic blue..

before..
http://img697.imageshack.us/img697/892/picture035r.jpg
http://img707.imageshack.us/img707/701/picture042g.jpg
http://img109.imageshack.us/img109/5986/picture044r.jpg

after..
http://img97.imageshack.us/img97/3673/picture110e.jpg

Next in order the intake manifold take new shape in colour!!

before..
http://img697.imageshack.us/img697/2917/picture05.jpg

after..

http://img696.imageshack.us/img696/8...cture028gv.jpg
http://img697.imageshack.us/img697/6568/picture030z.jpg
http://img171.imageshack.us/img171/9...cture051kc.jpg

Wish everyone Merry Christmas!!!

volkdent December 23rd 2009 03:29

Lookin' good!!!

Jason

NO_H2O December 23rd 2009 10:25

Go man Go. Nice work.

Jim December 23rd 2009 10:59

Thanks a lot quys!!!

Even i've passed in the dark side... your interest is still unabated..!!

Xellex December 23rd 2009 20:45

looking good :goodjob:

Jim December 24th 2009 13:23

Thx Xellex,really nice your project too!!

New OEM subaru oil pump introduced and one final layer of enamel in engine compartment!!
Next week more to come...

http://img686.imageshack.us/img686/7260/picture122.jpg

http://img686.imageshack.us/img686/5...cture123vq.jpg

http://img686.imageshack.us/img686/6767/picture128i.jpg

cu..

Scotts73SB December 24th 2009 23:46

Very nice!! Love that color ;)

Jim December 31st 2009 10:03

Thanks Scott!!

Well a few hours before end of the year last unexpected thing happened..
An old lady hit me with her car in the bumper but for my good luck my mechanic was there and with my insurance all the legal staff were arranged.

So, new polyester bumper will be introduced plus the painting job.

here are the evidence...
http://img39.imageshack.us/img39/6282/picture00054.jpg

http://img683.imageshack.us/img683/5...cture00055.jpg



so, its time again for engine update..

The block painted in silver colour and three more things that need to be painted is the water tube, valve covers and timing belt cover all in anthracite colour.
We will also re-locate the water tube in the back of the intake manifold so to achive better look from in front.

http://img138.imageshack.us/img138/3...cture00046.jpg

and..

http://img301.imageshack.us/img301/6...cture00049.jpg

and..

http://img9.imageshack.us/img9/4549/picture00051.jpg

and..
http://img707.imageshack.us/img707/8...cture00048.jpg


some other good stuff purchased and new piston rings and connecting rod bearings introduced plus new head studs!

http://img682.imageshack.us/img682/7...ture00063b.jpg

http://img138.imageshack.us/img138/4...cture00062.jpg

http://img192.imageshack.us/img192/8...cture00057.jpg

The re-assembly has begun and in the few next days I will be ready again to hit the roads!!

more to come from next year............

Wish everybody Happy New Year!!!

Jim January 11th 2010 10:28

At last... after 9 months without driving my beetle, finally the first ride take place this saturday in the road but now totally different then before.........rebuilded and painted:no:

The assembly of the engine is done and after painted is taking place back in to the engine bay and i must say that i am very pleased from the result.
Everything is in the right position as it has to be!!

http://img683.imageshack.us/img683/2...cture00080.jpg


http://img191.imageshack.us/img191/9...cture00087.jpg

The first 200km after the rebulid came very smooth and easy, the rev's didnt pass the 3500rpm.I have checked the oil and water level until the first change in 1000km.

GAZ struts in combination with bigger rear torsion bars provide better handling and gives you the feeling that it "reads" very well the road.

After the bumper will be replaced and painted by end of the next week some things may left to be introduced:

1.oil pressure gauge
2.bosch universal lamda
3.throttle reversed cable.


and a few photos from the first ride... ::)

http://img412.imageshack.us/img412/1...ture000899.jpg

http://img30.imageshack.us/img30/1489/picture000966.jpg

http://img196.imageshack.us/img196/760/picture00093.jpg

Scotts73SB January 11th 2010 23:34

Wow that fits right at home like its made to be there!
Great looking car!!
You got any radiator pics or plumbing? Always like to see how you guys come up with a way to do that.

Jim January 13th 2010 18:38

Yeah.....it fits right at home Scott!!Thanks by the way!!

I will post some pics from the radiator for you..

volkdent January 14th 2010 14:18

Very Nice, that's a great ride all away around.

Jason

Jim January 14th 2010 15:43

Thank you Jason! That is my goal, to keep the car in perfect shape all away around!!

effvee January 14th 2010 21:35

6 Cylinder Subaru
 
Hi, if you shorten the frame horns and move the engine/trans forward, is it possible to install the 6 cylinder in a super beetle? Sand Sport mag showed a story on the mods that can be done. The four and six cylinder shows great pormise?


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