Today I drove the car for about 100 meters. I did it at idle, with no linkage on the carburetors, no acceleration control. I was curious if the gearbox is working, and it does! I only shifted trough 1st, second and reverse and everything seems ok. The clutch engages good, the starter motor works perfectly. Then I placed the car on jack stands, and shifted through all the 5 gears. As far as I can tell for now it works! :D
Now I can concentrate on the engine more. I have this compression loss and oil leak between the cylinder and head at the piston no. 3, and probably have to flycut the heads to fix it...

A few new pics (sorry for the poor quality):
http://i260.photobucket.com/albums/i...0.jpg~originalhttp://i260.photobucket.com/albums/i...4.jpg~originalhttp://i260.photobucket.com/albums/i...8.jpg~original

The bug is back on the road again! :D :D And I can say that it's a different kind of animal! I just love it! I made about 200 kilometers with it (in and out of town) and I pushed it so hard that I managed to run out of gas :))
There are alot of small things that I still have to do, adjustments etc but the hardest part is behind me right now :D
http://i260.photobucket.com/albums/i...d.jpg~originalhttp://i260.photobucket.com/albums/i...1.jpg~originalhttp://i260.photobucket.com/albums/i...2.jpg~originalhttp://i260.photobucket.com/albums/i...1.jpg~original
http://i260.photobucket.com/albums/i...1.jpg~originalhttp://i260.photobucket.com/albums/i...3.jpg~original
Oh, anybody know a good online source for AN fittings and hose preferably in Europe? I can't seem to find any in my country...

It just looks so right! Very nice! but pls get those case ventilation pipes on the air filters connected to a breather box as your pulling in unfiltered air right now.

yeah, I have the large CSP breather box, and I also drilled and installed fittings in the valve covers, but I rushed to make the car fuctional for that week-end meeting, so I didn't have time to do everything right. I actually worked continuously one full day and a night, till 9 in the morning to get it done :P
Now I will concentrate on the details, I also want to make it Coil-on plug, like slowtwitch did on shoptalk. And a few other things.
I could really use some good oil fittings and hose for the oil cooler... probably AN, because the hose I have atm just doesn't want to stay put on the fittings with just clamps. Maybe if I get it crimped it will stay :P

Almost forgot: there is: http://www.isa-racing.com/katalog/
and over here www.racershardware.nl retails these parts. Very high quality, no chinese copies!

Cool car, nice color too.:thumbup:

thanks! Let me show you what I've been upto since the last update:
I revised all the wiring in the engine bay. Took out alot of not needed wiring. Mounted the voltage regulator where it's supposed to be. I made a small relay and fuse panel to have everything more organised.
http://i260.photobucket.com/albums/i...6.jpg~originalhttp://i260.photobucket.com/albums/i...9.jpg~originalhttp://i260.photobucket.com/albums/i...0.jpg~original

I converted it to coil-on-plug using the method I have read about on Slowtwitch's topic on shoptalkforums.
http://i260.photobucket.com/albums/i...2.jpg~originalhttp://i260.photobucket.com/albums/i...3.jpg~originalhttp://i260.photobucket.com/albums/i...9.jpg~original

I made a small vacuum collector for the MAP sensor:
http://i260.photobucket.com/albums/i...5.jpg~originalhttp://i260.photobucket.com/albums/i...6.jpg~originalhttp://i260.photobucket.com/albums/i...0.jpg~original

http://i260.photobucket.com/albums/i...0.jpg~originalhttp://i260.photobucket.com/albums/i...1.jpg~originalhttp://i260.photobucket.com/albums/i...7.jpg~original

I installed the crankcase ventilation system.
http://i260.photobucket.com/albums/i...8.jpg~originalhttp://i260.photobucket.com/albums/i...9.jpg~original

And after about a month, I started the engine again. Now it runs on COP wasted-spark. A small video:
http://www.youtube.com/watch?v=ARQdv55OuA8

nice work! Might take a gander @ slowtwitch's topic sounds interesting!

yeah it's quite simple and for me, just like everything I do to my bug, it was a challenge making it work. And it started the first try, I actually managed not to screw up anything.
Here is the topic with the description and schematic of the system:
http://shoptalkforums.com/viewtopic.php?f=1&t=131344

Hehe, I have another update already :D
I've started to understand relays a bit better, so I decided to take on a bigger challenge, and it worked! My beetle now has intermittant wipers with a programmable delay, and a wash/wipe function. I've been meaning to do this ever since I bought the beetle, and now thanks to Joel on aussieveedubbers, I found out exactly how to do it.

http://www.youtube.com/watch?v=aa0N-FMkFjI

I also installed a buzzer relay that goes on when you leave the headlights on, and open the door.

http://i260.photobucket.com/albums/i...h_DSCF5692.jpghttp://i260.photobucket.com/albums/i...h_DSCF5689.jpghttp://i260.photobucket.com/albums/i...h_DSCF5696.jpg

Love the wiper delay! Looking at something like that for mine. More info please :D

ditto that - ive some some room for some more relays :p

Joel did an awesome job on his "how to" topic on aussieveedubbers.com, and eaventho he drives a 1303 super beetle, he put out information for doing it on any other type of beetle as far as I can tell.
Here's the link to that topic, with all the info you will need. And my example is proof of that.
http://forums.aussieveedubbers.com/v....php?tid=86544

With all this talk and being in the middle of doing my wiring I went down to the scrapyard and got myself a '99' out of a 1995 Golf CL today!

Thanks for the link Xellex ;)

Ok, the 1700 engine was at the end of it's lifetime for sure, eating up oil and smoking like a locomotive, because of the badly worn out cylinder set, so I have decided to change plans on the 2L project, and just build a decent new-ish reliable engine, so I could enjoy my beetle more, and with no worries. The 1.7L engine will now become the long term "all-out" project, and in the meantime, I hope the bug will be running perfectly good. I wonder why I didn't think this up earlier...
That being said, the new engine is already up and running, I did the break-in and about 400 kilometers on it already.

The engine specs are:
2.0L type4 CJ case, with the plugs drilled and tapped.
2.0L crankshaft & rods.
New Mahle main/conrods/camshaft bearing sets. New connecting rod bushings.
Webcam 86A camshaft & matching webcam lifter set.
Original oil pump.
Original 2.0L Piston&cylinder set, honed and re-ringed.
1.8L heads (41x34 valves), just a little bit ported on the exhaust side, and new exhaust valves installed.
1.7L rockers, with the 8mm adjusting screw and the hydraulic shims/spacers instead of the spring.
Scat HD dual springs with the little spring removed.
Pauter HD spring retainers and hardened locks.
Elephant swivel foot adjusters.
228mm clutch.
All the rest, like cooling system, carbs, linkage, ignition system etc, comes from the previous engine.
Right now the exhaust is a hacked up original bus one, but not for long

I'm actually pretty happy with how the engine is performing, the only problem I had was with 2 elephant foot adjusters which exploded (on the same piston), probably because of me not clearancing them well enough. I changed those with original style, and no other harm was done.
I safely took it to 170km/h and it feels like it can do more :D

http://i260.photobucket.com/albums/i...8.jpg~originalhttp://i260.photobucket.com/albums/i...0.jpg~originalhttp://i260.photobucket.com/albums/i...9.jpg~originalhttp://i260.photobucket.com/albums/i...6.jpg~originalhttp://i260.photobucket.com/albums/i...0.jpg~originalhttp://i260.photobucket.com/albums/i...1.jpg~original

Here's a pic that I find funny:
I can honestly say that I have a 911 connecting rod in my engine. And a 930 one also :P
http://i260.photobucket.com/albums/i...1.jpg~original

I got a set of gsx-r throttle bodies today :D I'm hoping something nice will come out of these... I'm so eager to start the EFI conversion on my engine! I just love the challenge of always doing new stuff, things that look very complicated (if not imposible) in the begining, and all that it takes until you succeed.
http://i260.photobucket.com/albums/i...3.jpg~originalhttp://i260.photobucket.com/albums/i...2.jpg~originalhttp://i260.photobucket.com/albums/i...5.jpg~originalhttp://i260.photobucket.com/albums/i...4.jpg~original

Which ones did you get? 600s? or 1000!

actually these are from a 98-99 GSX-r 750. I searched all the topics and pictures I could find about the difference between engine types and years, and I think this model will fit best. That's because of the better injector angle, and the fact that they are 4 separate pieces, making it easy to space them apart for the IDF pattern.

Excellent. I did look at GSXR ones but found a better fit for what I wanted. Are the 750 the tapered 40mm-36mm ones? or are they a straight bore ones?

yes, they are tapered from 48mm to 40mm. I didn't measure the throttle plates but they are probably 46mm.
http://i260.photobucket.com/albums/i...0.jpg~original

:D should make some nice power! What EFI are you looking to use? Megasquirt?

yeah, I think the best choice in my case is going to be a Megasquirt ecu.

I'm tinkering again with the electronics in my car. First of all I managed to get the tacho to read the RPM correctly, thanks to a Dakota Digital universal tachometer adapter, recommended by Dave (owdlvr) in another topic here on GL:
http://i260.photobucket.com/albums/i...prd_zm_127.jpg
Thanks for that!

And after that I took on a bigger challenge: I got a universal central locking remote controlled unit, and this is how far I got today:
http://youtu.be/uQvVb8rrtqg
All that's left now is the mechanical part... installing the actuators etc.

While working on the wiring I stumbled upon a problem: The fact that the bug has a single bulb in the dashboard for both left and right turn signals. And that's run by a wire coming from the relay. That was messing with the central locking, and I managed to change it. Now it's much better and the interesting thing is that the battery voltage is much more stable now and the gauges are not dancing in the flasher's rythm anymore.

http://youtu.be/fjszkigvtjE

And while I was at it, I remembered Joel saying on the auusie forums that there's an accesory position inside the ignition switch. I wanted to test that, and after installing a missing wire, it works now. That opened up some new posibilities for tinkering :P

http://youtu.be/SOey4ggivus

Sweet, I'll be staying tuned to see how you make those gsxr TB's work.

Some good work. The cl system looks a lot like the one I have to install on the bug. And the 'x' position on the ignition switch will be invaluable, I'm thinking that you xuls alao put things like the fuel pump priming pulse on it too. I'll be using a relay off it to push to an accessory circuit and fuses.

The very simple wiring diagram I started with got very complicated!

So simple yet so effective.

Perhaps cooler than the key contacts, there's another Dakota Digital module that controls the headlights/domelights/and gives you retained power without presence of the key...Built-in battery voltage monitoring, adjustable timers, adjustable light sensitivity for automatic headlights, etc.

http://img.photobucket.com/albums/v2...8.jpg~original

So auto headlight and control of the courtesy light?

Courtesy light I'm going to use a Ford yellow relay. Auto headlights aren't something that I've thought about

What Does the retained power do?

http://www.dakotadigital.com/pdf/PAC-1300.pdf

that's very interesting but I just got a few modules from the local market, and they will cover most of these things. I'll post them as I go ;)

Excellent, just noticed you were using the other DD product and doing similar projects - I'll be looking forward to seeing the other options available. :goodjob:

It's so damn cold outside for a few weeks now, that I really can't do much but sitting in front of the PC, so I'm working on a side project. Hope you guys will like it:
www.vw1303s.com

Finally, I finished my exhaust header. Don't laugh at me too hard, it's my own design, and I worked with the tight space I had under the bug.
http://i260.photobucket.com/albums/i...1.jpg~originalhttp://i260.photobucket.com/albums/i...3.jpg~originalhttp://i260.photobucket.com/albums/i...0.jpg~originalhttp://i260.photobucket.com/albums/i...4.jpg~original
I't all stainless, with equal length primaries, and merged according to the firing order.
The muffler is from some motorcycle (yamaha R1 I think).
Welded the bungs and soon I'll have a wideband O2 system and EGT reading :D
http://i260.photobucket.com/albums/i...4.jpg~original
Drove it a few km's tonight and as far as I can tell, my bug has never been so silent before, which I like very much lately.
Better pics coming soon.

Well done! Only some transitions are a bit abrupt (not curved), but its a unique design indeed!

yeah, that's because I was a cheap-ass and couldn't convince myself to buy a few more 50mm diameter bends...
I guess you can easily figure out the reason why the collector is oriented to that position, and where I got the inspiration from :P

better pics:
http://i260.photobucket.com/albums/i...2.jpg~originalhttp://i260.photobucket.com/albums/i...5.jpg~originalhttp://i260.photobucket.com/albums/i...3.jpg~originalhttp://i260.photobucket.com/albums/i...7.jpg~original

http://i260.photobucket.com/albums/i...1.jpg~originalhttp://i260.photobucket.com/albums/i...4.jpg~originalhttp://i260.photobucket.com/albums/i...9.jpg~originalhttp://i260.photobucket.com/albums/i...7.jpg~original

Hello, I am trying to fit projectors on my car, and i saw your project. What is the black thing that you used to move away the glass from the projector? Did you do any other mods on your fender? Thanks in advance.http://i260.photobucket.com/albums/i...1.jpg~original

hi, I used some epoxy resin and it's black because I wrapped that part in black masking tape. It's not the greatest solution, and I'm gonna try to remake them when I get some free time.