GermanLook Forums - Oval Bugster

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- - Oval Bugster (https://www.germanlook.net/forums/showthread.php?t=11514)

that looks awesome :D

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

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.

Quote:

Originally Posted by SuperRSi (Post 87103)

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.

Honestly, though having it in this state ads a bunch of extra ease for finish work, I would seriously consider just building a tube chassis and mounting all the components onto it next time. I like everything this chassis has to offer, but what a biotch to fit!!!

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

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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?

This build is just bonkers:eek: so much work :cool::cool::cool:

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!

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