Bugaru Project
 

I thought the time has come to share with you my little suby project..

Some infos:

Super Beetle 1303 '73
EJ20NA JDM 125hp with stock ECU and stock for now tranny
Two fans ventilated system with custom air box
Custom exchaust with sport catalytic converter
New intake air system
Kafer cup brace (lightweight)
Kerscher wings 4cm front and 6cm rear
Versa struts with sport springs & Koni suspension inserts
Sway bar 7/8 front and 3/4 rear
Porsche cup3 Twist wheels
Ventilated front & rear porsche disks 282 & 289mm
Rear 3.5cm spacers
Vdo speedometer & tachometer
Smoked rear lights
Quick shift from Empi
Sortened oil sump(from Martins Bott)
Custom interior trimming
Imperial Blue color
Strut bar

Future plans are to plug a new stand alone ECU with new program and also a Rancho transaxle and maybe a NOS...

Here are the pics..

http://www.imageshack.gr/files/d9coq...a7hw_thumb.jpg(EJ20NA)

http://www.imageshack.gr/files/q7k97...lbi0_thumb.jpg(sortened oil sump)

http://www.imageshack.gr/files/c1fpj...0v5d_thumb.jpg(porsche 944 single pot calipers)

http://www.imageshack.gr/files/esi1p...ffzw_thumb.jpg(his lungs)

http://www.imageshack.gr/files/u6gzd...d4z8_thumb.jpg(still on project)

Next week i have planned to create a brand new stainless exhaust system and drop the suspension at the front.
Another thing is to buy a pair of spacers for the rear wheels.

Stay tuned...

Rgrds,
Jim

and couple more..

http://www.imageshack.gr/files/9d9m9...49fp_thumb.jpg

http://www.imageshack.gr/files/5kcy0...jed7_thumb.jpg

http://www.imageshack.gr/files/q5608...gn4h_thumb.jpg

http://www.imageshack.gr/files/0oqtm...997k_thumb.jpg

http://www.imageshack.gr/files/w84gy...nor5_thumb.jpg

...

http://www.imageshack.gr/files/qbkn0...wchb_thumb.jpg

http://www.imageshack.gr/files/d5ygc...td3h_thumb.jpg

http://www.imageshack.gr/files/9ao3v...zt85_thumb.jpg

How is that power with the EJ20 NA? I have the same motor in my standard, but I'm just getting the car together and haven't had a chance to unleash the ponies. Did you use the stock ECU or an aftermarket? I'm using Megasquirt. I'm interested in how your progress is going, good work!

Casey

I can chime in on the power..

I drove Martin's (Bugat5speed) car, with a 1.8 lt and a 5 speed, and was very impressed on the roads we drove. Very easy drive on public roads, with power to pass.

Not sure what your plans are, but I would think the 2 lt would be a little more torque than the 1.8. If its a DD, and part time fun car, definitely enjoyable and powerful.

If full out track, then you may need something more powerful than 140-150 Hp.
Alex

For some reason I can only see half of the pics when I click on them.

Did you move the transmission forward to make the motor fit ?

Rob.

Hi

Nice work, is your motor DOHC or SOHC?

Rob,You need to scroll across on photos, I did the same thing.

Steve

Thanks guys for your kind words,this gives me the motive to keep the hard work!!

cfordyce05 ..I can't tell you how is the feeling of driving the car because i've to wait in order to install the exhaust system.
At the moment i use the stock ECU but I'm planning to install a paraller ECU (called Dastek).

Rob..when you load the picture, hit a click on it and then you will be able to see the picture fit on screen.
No,I didn't have to move the transmission forward(everything remain on stock location).

Steve..The motor is the SOHC one and it is perfectly fitted on stock engine area.


Before & after the front drop
http://www.imageshack.gr/files/219cg...ecwr_thumb.jpg

http://www.imageshack.gr/files/j1czx...v39t_thumb.jpg

EJ20 SOHC(fits perfect!!!)
http://www.imageshack.gr/files/ykhie...a9io_thumb.jpg

Stock vs Widened!!
http://www.imageshack.gr/files/8vs5k...caqz_thumb.jpg

Watercooled
http://www.imageshack.gr/files/fdp92...xt6k_thumb.jpg

More pics to come..

Hey Jim, hows your project going? I finally got my car with the EJ20 NA on the road. It's turning into a pretty fun car to drive as I get "bugs", no pun intended, worked out. So far my main concern is airflow to my radiator. I have mine mounted on the firewall drawing air from the louvers under the rear window. At highway speeds, I think the airflow over the car is creating too much of a low pressure zone and not allowing the fans to suck as they should. I was thinking about trying a small spoiler over the rear window to break up airflow over the car and create a high pressure area to help the fans out. As soon as I slow down, it starts to cool off. So far it has gotten up to 214 degrees, and that was with 45 degree weather! With the deck lid off I have never had it that high while driving. I plan on starting a car profile to document my conversion, but haven't had time with school and marriage. Good luck with your conversion! Once I get my fuel tuned up pretty good, I'm going to take the car to a dyno and tune my spark. I'll let you know what kind of numbers I get.

Casey

Hi Casey,

Keep going with your project I think it deserves the money and time we have spend!

You can see in the following link were is the last update in my project.
I have had some troubles with the VSS sensor but this already belongs in the past!!! http://forums.aussieveedubbers.com/v....php?tid=67945

Now from what i have heard from other forums the best way to manage the airflow in the radiator is to place it at the front of your car(if it is a super,you have more space to use).
Mine is placed at the front with an extra fabricated sheet of metal between the front halls and the radiator and after many hours of driving the water temp was never pass the 80 degrees:D .
If you want more advice in your current setup then why you shouldnt try to search in the above forum such also in Germanlook...i think both sites have the knowledge & answers in your concerns.

Do not forget me with the Dyno results:D :D :D

Cheers,
Jim

Nice project car, man.

Keep us posted,

Thanks

Hey, Your car is looking good from what I saw on the other thread. I have taken a big step towards my cooling issue. Just by adding a scoop over the rear window vents, I am now down to about 182-186 cruising and 189-191 under load going up hills and hard driving. This was at 60 degrees out instead of 45 degrees. That is a great improvement over 214! My dyno run should be fairly soon because I have my fuel pretty much sorted out.


Casey

update...

after a lot of work be done in the car by my self and long time since my last post,finally (after a big and unexpected surprise gift from my lovely wife!!!!)the car painted in this beautiful imperial blue perl color!

Next to come is to finish the interior upholestry by the end of the month and soon it will be back to roads again!!!

here is the result until now..

http://img142.imageshack.us/img142/4330/dscn1463uu4.jpg

http://img55.imageshack.us/img55/5921/929qw3.jpg

http://img55.imageshack.us/img55/4499/931xv3.jpg

and..

http://img360.imageshack.us/img360/2307/922nw6.jpg

http://img383.imageshack.us/img383/4616/935xk7.jpg

http://img241.imageshack.us/img241/2499/909sp8.jpg

http://img114.imageshack.us/img114/2397/941ed7.jpg

http://img412.imageshack.us/img412/3618/944sx0.jpg

http://img114.imageshack.us/img114/3336/dscn3298vu2.jpg

http://img412.imageshack.us/img412/7370/952jg9.jpg

http://img241.imageshack.us/img241/4734/927ik3.jpg

http://img241.imageshack.us/img241/203/022jk4.jpg

http://img412.imageshack.us/img412/6946/947hb5.jpg

more to come..

Very nice!!! I had a 74 super painted a similar color. Royal Saphire Blue Metallic, but two tone with white on the side. Looks nice.

What's the paint code on that blue?

Thanks mate!

the color is called imperial blue and it's came from Ford Focus RS.

Rgrds,
Jimmy

update..

http://img88.imageshack.us/img88/9338/dscn3322ym1.jpg

http://img204.imageshack.us/img204/9986/dscn3308sy0.jpg

http://img233.imageshack.us/img233/2064/dscn3321ue0.jpg

http://img137.imageshack.us/img137/4624/dscn3317fu8.jpg

http://img291.imageshack.us/img291/4645/dscn3303ty9.jpg

http://img523.imageshack.us/img523/6...ture050cd0.jpg

http://img509.imageshack.us/img509/3...ture055ge6.jpg

http://img112.imageshack.us/img112/4...ture054qm6.jpg

http://img112.imageshack.us/img112/9...ture057dt2.jpg

Nice job!!!

Jason

Thanks Jason!

I'm pretty happy with the result so far and planning more things to run after I complete the interior.

How is your project going??I'm really impressed from your progress!

Nice job.

Thanks quys!

Some more from the back seat and fuse box..

http://img56.imageshack.us/img56/3694/dscn3351pq7.jpg

http://img98.imageshack.us/img98/2048/dscn3346so4.jpg

http://img89.imageshack.us/img89/6296/dscn3349pn2.jpg

Finally side panels were finished and also attached in the rear 2 nice oval speakers from JBL(and maybe a new source to running them):D :D :D .
Next and final finish will be the front seats!

so for now..

http://img233.imageshack.us/img233/8418/986bl8.jpg

http://img120.imageshack.us/img120/5154/988iv1.jpg

http://img120.imageshack.us/img120/7...ture060sw8.jpg

http://img356.imageshack.us/img356/6...ture059hi4.jpg

Looking REALLY good!!!

update..

Finally we decided to make the bottom of the front seat independent (in three pieces) in order to be more like a bucket style.
Hope until Thursday it will be completed and ready for install the one piece windows kit!

http://img88.imageshack.us/img88/6479/picture033um9.jpg

http://img227.imageshack.us/img227/4...ture035sv9.jpg

http://img136.imageshack.us/img136/2...ture036jc0.jpg

http://img528.imageshack.us/img528/2...ture043iy0.jpg

cu

Its on the wrong side!! I hope you have the other one? I must say the interior certainly looks very professional.

evilC

Hey evilC.. thanks for the compliment mate ,but I'm really confused about what you say::cool:

"Its on the wrong side!! I hope you have the other one?"

Rgrds,
Jim

The seat is supposed to be on the left side infront of the steering wheel otherwise you can't reach the pedals:lmao: :lmao: But hey it could be REAL cool if you could drive it from the right hand seat:cool:

evilC

hahahahahaha!!!and i was looking for ,from what you said, what is going wrong in the hole picture!!!hahaha!!!!

Cheers!

Thats British humour for you! Thats why we had an empire and lost it - no-one could understand the jokes

evilC

more update..
I'm pretty excited with the result, the car looks fantastic and i'm curious to hit the roads again!!!!

some pics in random appearance..

http://img529.imageshack.us/img529/8...ture052if9.jpg
http://img529.imageshack.us/img529/p...jpg/1/w640.png

http://img266.imageshack.us/img266/6...ture048mk1.jpg
http://img266.imageshack.us/img266/p...jpg/1/w640.png

http://img237.imageshack.us/img237/5...ture047oj4.jpg
http://img237.imageshack.us/img237/p...jpg/1/w640.png


http://img167.imageshack.us/img167/5...ture055vf1.jpg
http://img167.imageshack.us/img167/p...jpg/1/w640.png

http://img530.imageshack.us/img530/7...ture060wy4.jpg
http://img530.imageshack.us/img530/p...jpg/1/w640.png

:eek:

that's one fantastic looking bug right there, 2 thumbs up

excellent! this being very beautiful!, jim you can communicate with me? ferfre007@hotmail.com

Hey Jim, awesome results dude... Congrats
Who did your paint job and upholstery?

Chris

Finally his back at home...some adjustments needs to be done and then we will enjoy many many rides!!!

and two photos from his first trip..


http://img125.imageshack.us/img125/7...ture134ou5.jpg

http://img155.imageshack.us/img155/5...ture131ms1.jpg

Beautiful work,

Congrats.

Alex

Thanks Alex!

How is your progress going??

Man, I hope my ride comes out looking as nice as yours. I keep coming back to your ride and just starring in awe.

Jim,

Thanks for asking.. Its going a little slow, had some serious pan head issues over the summer, finally decided to get a new chassis, but after removing paint discovered that it was equally damaged. Then I decided get some proffesional help to repair the existing chassis, that went slow do to sourcing a new pan head, and some work overlow at their shop..

Good news is that my pan head should have arrived today, so no my chassis will get full attention, which means blasting, spot repairs, pan head replacement, new pans, some AN fittings for fuel through the tunnel, and a new paint job..

Hopefully after that I can turn my attention to the suspension, my 5 speed box, and brakes that have been sitting around so now I have clean all that up..

Once that is done, I am sending the body off for repair and paint.. hopefully that won't be as much of an issue..

Other than that, going ok ;)
VR
Alex

Well,

After lot of time thinking of which is the best strut insert for my setup, finally decided and ordered 2 pairs of Gaz adjustable inserts. These units can be built in various open and closed lengths and will adjust bump and rebound off a single control knob.

The rear end has been droped 3cm,new 944 (23.5mm) torsion bars were introduced and also a pair of wheel spacers were bolt in the rear brakes for extending the length of each side for 5.5cm!

I have also in mind to buy a new lamda sensor (universal bosch) for my suby as this one is passed away.

More pics to come when the new inserts arrived and install.