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amazing build...
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that looks awesome :D
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Picked this little guy up for the A/W intercooler rad. It's a stock 996/986 center rad, about $170 so I thought that was reasonable. Has about 3/4" inlet/outlet. Unfortunately I don't have any more room around the rad, so it's going to have to find a place somewhere else in the car...
https://fbcdn-sphotos-d-a.akamaihd.n...07635871_n.jpg Jason |
Getting there, working on the A/C system and getting the stuff under the hood to work out nicely...
https://fbcdn-sphotos-d-a.akamaihd.n...83553186_n.jpg https://fbcdn-sphotos-f-a.akamaihd.n...99715771_n.jpg https://sphotos-a-sjc.xx.fbcdn.net/h...79772951_n.jpg https://sphotos-a-sjc.xx.fbcdn.net/h...18394275_n.jpg https://sphotos-a-sjc.xx.fbcdn.net/h...91905898_n.jpg https://sphotos-a-sjc.xx.fbcdn.net/h...91275857_n.jpg https://sphotos-b-sjc.xx.fbcdn.net/h...91094240_n.jpg https://fbcdn-sphotos-d-a.akamaihd.n...78222133_n.jpg https://sphotos-a-sjc.xx.fbcdn.net/h...08038409_n.jpg Jason |
Nice!
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Awesome work!!!
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What a great build. I had considered this and your posts have convinced me not to! But Wow will you end up with a nice ride.
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Jason |
Back at it, just grinding through the details.
Fabbed up these steering column brackets, I now have a tilt AND telescoping steering wheel!!! This little bracket was a lot of work but now I can adjust the wheel for almost any seat or seating position. The nutsert tool is already paying for itself! https://sphotos-a.xx.fbcdn.net/hphot...26666443_n.jpg https://sphotos-a.xx.fbcdn.net/hphot...22532922_n.jpg https://sphotos-a.xx.fbcdn.net/hphot...11666522_n.jpg https://sphotos-a.xx.fbcdn.net/hphot...16528036_n.jpg Finished up moving the clutch master over 1.75" as well. It's not what I would call pretty, but I'm working on my side under the dash so cut me a little slack. It is all sealed and if I ever do a renovation of this thing I can pretty it up then. https://sphotos-b.xx.fbcdn.net/hphot...89121094_n.jpg https://fbcdn-sphotos-h-a.akamaihd.n...55634056_n.jpg https://sphotos-a.xx.fbcdn.net/hphot...04781063_n.jpg Steering column back in and we have steering again!!! https://sphotos-b.xx.fbcdn.net/hphot...08086189_n.jpg https://fbcdn-sphotos-a-a.akamaihd.n...76254614_n.jpg Finalized the angles, routing, and rotation of the tubes for the cooling system. I think Erik at norcalsandandoffroad got them welded up for me today. I do all the fiddley work and I let the pros do the talent stuff! https://fbcdn-sphotos-c-a.akamaihd.n...54295149_n.jpg https://sphotos-a.xx.fbcdn.net/hphot...29694179_n.jpg These are the details I'm most proud of, I was able to utilize the stock coolant pipe bracket even though my pathway is totally different. https://sphotos-a.xx.fbcdn.net/hphot...60507800_n.jpg Jason |
Fantastic work! Looks like things are getting a little tight now eh?
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Oval bugster
This build is just bonkers:eek: so much work :cool::cool::cool:
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Hi Jason,
Good to see things progressing at a constant pace, nice to see the go-kart, must give some good motivation! I might not be commenting much but rest assured I'm watching ;) Rich |
More coolant work. Had to "massage" the area above the front lower control arm attachment point to allow space for the rad. Not pretty but necessary. Also welded a tunnel through two body layers for lower rad hose.
https://sphotos-a-lax.xx.fbcdn.net/h...63258738_n.jpg This is where the tunnel exits, then up and over the rack bellows. Tight fit. https://sphotos-a-lax.xx.fbcdn.net/h...75101036_n.jpg The top and bottom hoses join next to the gas tank. Also this is a high point for the lower tubing, so a bleed bung has been added that ties into the stock Boxster coolant bleeding system. Hopefully this makes for trouble free bleeding. Very excited to be able to use the factory coolant hose bracket! https://sphotos-a-lax.xx.fbcdn.net/h...01701844_n.jpg The previously dual rad system now only has one pathway. Both side bleed tubes can be seen and will be used. On a technical note, I am now aware that there are special hose clamps for silicon hoses. They have an additional internal sleeve that offers a smooth surface for the silicon to be squeezed by. https://sphotos-b-lax.xx.fbcdn.net/h...07621350_n.jpg https://sphotos-b-lax.xx.fbcdn.net/h...63077504_n.jpg I've been able to just squeeze this monster in there, next up add the A/C condenser... https://sphotos-b-lax.xx.fbcdn.net/h...22741332_n.jpg Jason |
Coming along Jason. Very cool project!
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Small update, big progress.
I finally got the floor pan welded to the frame. It sounds simple enough, but the floor pan has a nice thick layer of German underbody sealer on it, and it all had to be ground back from the welded edge. A big mess. Then, to make it just a little more messy, I seam sealed the whole area. I forgot to get a pic, but I used a honey consistency seam sealer so I could really flow it into all the nooks and crannies. Trouble is I'm doing this upside down so I looked like I pigged out at the chocolate fountain... Also got a jack point welded in, seen it the top part of this pic. Anyway, here's a shot pre-sealer. https://scontent-b.xx.fbcdn.net/hpho...83792484_n.jpg And a couple more of the rad area. https://scontent-b.xx.fbcdn.net/hpho...20646262_n.jpg https://scontent-a.xx.fbcdn.net/hpho...42974796_n.jpg Jason |
Big day, I finally came up with a structural solution that is also elegant in its design. It ties the inner and outer Boxster chassis, the new frame rails, and the roll cage together, all while allowing a nice edge to finish the bug/Boxster seam along.
https://scontent-b-pao.xx.fbcdn.net/...84078532_n.jpg https://scontent-a-pao.xx.fbcdn.net/...77634780_n.jpg https://scontent-a-pao.xx.fbcdn.net/...26126717_n.jpg https://scontent-b-pao.xx.fbcdn.net/...68460668_n.jpg https://scontent-b-pao.xx.fbcdn.net/...11546750_n.jpg Also finishing up a factory-like re-attachment of all the lines running back to front. https://scontent-b-pao.xx.fbcdn.net/...19901253_n.jpg Jason |
Starting to get fun. Installed the stock Boxster trunk latch.
https://scontent-a-sjc.xx.fbcdn.net/...58562936_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...35928109_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...65200045_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...16288989_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...51814064_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...65873892_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...55275867_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...62070908_n.jpg Jason |
Devil is in the details. There was a fatigue fracture through this area. Hope this makes it better and the decklid easier to seal against water.
https://scontent-a-sjc.xx.fbcdn.net/...62572045_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...96832355_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...70404975_n.jpg Jason |
Just curious about something, I scrolled back a few pages but maybe I missed it. How does the wheelbase look front to back? I mean does the top curve of each wheel line up with the curve of the fender? My super was in an accident years ago and I went through quite a bit just with small changes here and there to get everything to line back up.
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I can't see a difference, although apparently there is one. Keep in mind I have fiberglass fenders, so it's really easy to modify the opening too. I believe the difference is less than 3/4"' and I like my front wheels a little tucked forward a la Foose.
Jason |
More body mods. Not too many things good about getting old, but a couple are patience and knowledge, so I scraped up as much of each as I could and this is what happened.
https://scontent-a-pao.xx.fbcdn.net/...71667986_n.jpg https://scontent-a-pao.xx.fbcdn.net/...20922168_n.jpg https://scontent-a-pao.xx.fbcdn.net/...91554547_n.jpg https://scontent-a-pao.xx.fbcdn.net/...10043420_n.jpg https://scontent-b-pao.xx.fbcdn.net/...34955743_n.jpg https://scontent-b-pao.xx.fbcdn.net/...71598732_n.jpg https://scontent-b-pao.xx.fbcdn.net/...31581513_n.jpg https://scontent-b-pao.xx.fbcdn.net/...72869743_n.jpg |
Slow, tedious progress, but progress nevertheless.
Built the template for the side storage pods, the drivers side will house the rear relay block. https://scontent-b-sjc.xx.fbcdn.net/...41137063_n.jpg To close off the frame rails, I built a plug that also includes a nut to affix a bracket for the trailer hitch. I see myself building a trailer that I can haul track tires with and that is also a tent someday. https://scontent-a-sjc.xx.fbcdn.net/...18620866_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...44934077_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...92682715_n.jpg The inner fender seam between the Boxter and the bug is almost complete. Built a panel that merges the strut mount to body. https://scontent-a-sjc.xx.fbcdn.net/...54505894_n.jpg https://fbcdn-sphotos-b-a.akamaihd.n...33183846_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...44716544_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...10552230_n.jpg Jason |
Little update:
Got these aluminum mufflers, yes, I said aluminum. Got a buddy that builds big HP cars and he swears by them, very, very light, no cracks yet for him. I'm doubtful, but they aren't that expensive and I could flange them to a stainless system if I wanted and still get big weight savings. https://scontent-a.xx.fbcdn.net/hpho...82146545_n.jpg Ditto for cheap Chinese headers. They are supposed to be stainless, and they are except for the severely warped flange. Had to spend a bunch of time on them to get the flange flat and to open the bolt holes up. Really surprising how simple some of the mistakes are, but equally surprising how little a complete header setup was. https://fbcdn-sphotos-g-a.akamaihd.n...92183244_o.jpg Working on the fitment to the fenders, these will have to be widened ever so slightly unless I like the smell of burnt rubber around every corner. Looks kinda cool though... https://scontent-b.xx.fbcdn.net/hpho...58302321_n.jpg https://scontent-a.xx.fbcdn.net/hpho...73219011_n.jpg https://scontent-a.xx.fbcdn.net/hpho...35340928_n.jpg https://scontent-b.xx.fbcdn.net/hpho...33837085_n.jpg Finally got the condenser attached to the rad, used aluminum spacers my wife uses for her business, re-threaded them for metric, and had Eric at NorCal Motorsportz weld them on for me. https://scontent-a.xx.fbcdn.net/hpho...66570364_n.jpg https://scontent-b.xx.fbcdn.net/hpho...16145612_n.jpg https://scontent-a.xx.fbcdn.net/hpho...48473959_n.jpg https://scontent-a.xx.fbcdn.net/hpho...63643835_n.jpg A before shot of the area I need to fill between the Boxster chassis and the tubing. https://scontent-b.xx.fbcdn.net/hpho...15329369_n.jpg https://fbcdn-sphotos-g-a.akamaihd.n...52902058_n.jpg The mess I have yet to tackle... https://scontent-a.xx.fbcdn.net/hpho...30647322_n.jpg Jason |
Looking good Jason.. Did you see that there's another one that appeared recently, on the front cover of the new Ultra VW magazine..
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cOOL!!! How can I get UltraVW over here?
Jason |
I'm pretty sure you can either buy a single issue or they do electronic copies too..
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http://www.ultravw.com/uploads/uvw/a...1/novcover.jpg It's available in iTunes -- https://itunes.apple.com/gb/app/ultr...525983654?mt=8 |
Just noticed you're using Vibrant mufflers. My first job out of Uni was with Vibrant, product development and tech support. Nice choice!
-Dave |
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http://www.vwheritage.com/blog/2013/...orsche-beetle/ :cool: |
I bought the online version. The interior is amazing, but it's clearly a street car that won't see much track time, like the Bugster, and I really wonder what the thought process was on leaving the rear edge of the rear fender as odd as they did. In the article they mention doing an early version, boy are they in for a surprise. Every one of these conversions I've seen have been Supers, the early body is soooo much smaller, like building a ship in a bottle!
Dave, what are your thoughts on aluminum exhaust systems? I'm sure they would have a hard time holding up on multiple rally stages, but what about a street car? Jason |
The details continue - gauge cluster now.
Cut the stock speedo ring and moved it over 1.5". It was really tricky because I couldn't put the cluster in level, didn't flow with the curves, and it couldn't flow with the curve because it would look too tilted, I ended up with a compromise between the two. https://scontent-b-sjc.xx.fbcdn.net/...69449247_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...30458955_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...41256817_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...30858452_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...41406731_n.jpg https://fbcdn-sphotos-f-a.akamaihd.n...37121392_n.jpg Jason |
Front and rear latches will be controlled by stock solenoids. Deepest part of front latch aluminum will be embedded in fiberglass to bond it to inner hood surface.
https://scontent-b-sjc.xx.fbcdn.net/...04152730_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...17804218_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...24784218_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...77396155_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...25698219_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...81382168_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...54154908_n.jpg https://scontent-a-sjc.xx.fbcdn.net/...66168637_n.jpg https://fbcdn-sphotos-c-a.akamaihd.n...53976449_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...73517595_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...00593643_n.jpg https://scontent-b-sjc.xx.fbcdn.net/...52182829_n.jpg |
Dirt is still being moved on our hillside, should have a flat spot to build a 26'x40' shop next week. 0 progress on this project, of course things take more time than you expect to get rolling.
Here's a shot of a Super/Boxster S from Sweden, hope to be doing this in my bug next year. https://vimeo.com/m/99021642 Jason |
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A bit off topic but that porsche look alike track car is an awesome built as well! https://plus.google.com/app/basic/ph...ource=appredir |
Oval Bugster
digging this build big time
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Updates?? :driving:
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Nada, I've been tinkering with the UBRDUB, hope to have fixed a coolant leak, but really just treading water till I get the finals for permits on the new shop. It's very strange to go from working on something so complicated and exciting to essentially nothing. For the past year I've done less mechanical work than changing the oil... I'm seeing maybe 4 or 5 more months before I'm into the thick of it again. I can promise you that unless I die or something really crazy happens I'll be finishing this thing. I definitely have not lost any interest, in fact the delay has made me want it even more and given my mind a little rest that it probably needed.
On a side note, looks like using images off of my Facebook page wasn't a great idea, most of the link look broken, I'll have to get everything repaired and maybe host on Instagram? Jason |
You seen this?
http://vtwoconcept.com/2-7l-boxster-beetle/ Also, this guy say the wiring harness can be simplified a lot: http://forums.pelicanparts.com/porsc...ine-awd-2.html |
I'm glad this project is still going. It is just amazing to watch it go together. It is too bad so many of the pictures are missing. I was wanting to share this project with a friend and did my best with what we can still see. I use photobucket for what I post online. Definitely looking forward to seeing more when you are able to work on the bugster again
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All the pictures have disappeared?!?!?!
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