Time attack beetle

[Humble]

So frustrated, I put the on the back burner for now and tried to fit the new front bumper and brackets to see hom much I need to widen it. Brackets and bumper aren't even close. I got 2 different front bumpers and neither fits, so that will need to be modified. I should have taken pictures but I forgot to.

Next, I tried test fitting the radiator in a few different positions to see what could work and what wouldn't.

(A)


(B)


(C)
Had to trim the front section of the spare tire well some more to get this to fit


(D)
pretty much like (B) but a slightly different angle and different bottom mount


Originally my plan was to route radiator exhaust through a hole in the hood ala mitsu evo 8/9. But if I can get enough clean flow to the fender wells I won't cut the hood which will probably look better (stealthy) anyway. I also need to make sure there's enough room for the radiator for the air-water intercooler.

[Humble]

I also took the motor out and cleaned it up a bit, flipped it over and got some detailed shots of the exhaust and oil pan. I pulled the oil pan off and it's soaking to remove the oil so I can start hacking it up. The exhaust will come next.










That's it for now, I think my rollcage maybe on it's way. I decided to go with a RLR weld in cage for racing. I plan on topping out at 150mph/240kph on the track with this tranny and wheel combo and I want something I can trust if the worst should happen.

[ccain529]

OH WOW!! The more I look at Subby conversions, the more I want one!!! Great job! You are doing some awesome work! Keep the updates coming!

Cheers

Cheech

[Mikey]

Sweet looking project. I like the pictures of all the new parts laid out. Another Suby conversion. Looks great!

You asked about the fuel sender. For my set up, I bought a universal sender and the correct guage from Summit. I'm also using Autometer guages, I spotted the yellow boxes. I tried to figure out the resistance of a stock sender. I figured either go with their gauge/sender and know for sure it'll work, or guess. I'd rather not guess with something like that.

Belt? The rope is a good idea. I worked for a little while at a truck part store. They had a guage to measure old belts if the numbers are worn. That might help in some way. They had a HUGE rack of belts. I know, I stocked it.

I have a thread for my project, it may or may not help with your subaru conversion. http://www.germanlook.com/Forums/showthread.php?t=7050
There is also a Subaru advice thread, it may or may not help. Just thought I'd throw it in here too.
http://www.germanlook.com/Forums/showthread.php?t=6676

My only advice would be to raise the engine and transmission for better ground clearance. Also, it looks like the exhaust is as low as the oil pan. So why shorten it? I shortened mine and I almost wish I hadn't. I didn't gain much ground clearance.

Just my 2 cent.

[SuperRSi]

Which exhaust is that? OK another silly request... if you unbolt your exhaust and have time, please spin it around and see if it bolts on backwards and misses the cam covers. I am building a STi Manx and would like to reverse the entire exhaust/turbo, intercooler, and intake manifold. I just have not had time to take the stock exhaust off. So I was hoping you might be unbolting your header....hmmm.

Thanks,
Randy

[Humble]

Not much done today, got a pretty godd tan (burn) from spending all day thurs working on the car in the sun.

Mikey:
I really dig how you laid out the gauges in your dash I wanted to do something similar but put the tach and speedo in the center of the dash and the rest behind the wheel. I thought about hacking up the dash a little bit just to mount the tach and speedo higher for better view.

I want to shorten the oil pan but widen the bottom so i don't lose overall capacity and raise the engine but as little as possible to keep all the weight as low as possible. The exhaust actually hangs lower than the oil pan by almost an inch and nearly touched the ground when i got in the car

SuperRSi
No problem, all the nuts were finger tight. The exhaust is a megan racing header from ebay, I tried a couple different ones but settled on this one. I tried to fit it on backwards for you but the up-pipe doesn't clear the cam cover and to make it work you would have to add a few inches to the bottom of the up-pipe next to the flex coupler to make it clear.

[Humble]

So far my hunt for the correct clutch master cylinder has been unsuccessful. I've had a lot of "that should work" but no hard calculations so I tried to figure it out on my own. I don't want to go through the whole return process (or eat the cost) of 3-4 MC's to find one that works.

*warning math ahead*

If you start with the presure plate and work backwards it makes a little more sense. Next in line is the throw-out arm, where the bearing side is 1.5" from the pivot and the cable eyelet is 3.5" from the pivot providing a ratio of 2.3:1.
The slave cylinder and master cylinder also have a ratio (at least with my preliminary setup on paper, I haven't commited yet incase this math is horribly flawed). I have a clutch master that's 1" diameter and a slave that's .88" in diameter giving a 1.136:1 ratio. and Last I have a tilton pedal assembly that's 5.5:1 pedal ratio.

So here's what I came up with:
Pr = force needed to release presure plate ie 3000# (guessing here)
T = thowout arm ratio on 091 tranny 2.3
M = master cylinder/slave cylinder ratio 1.136
Pa = Pedal assembly ratio 5.5

((Pr/T)/M)/Pa=Pedal force
or
((3000/2.3)/1.136)/5.5=208.76# at the pedal

Now playing with the values a little bit produces more realistic results but the biggest unknown is how much force it takes to release a KEP 3000# presure plate. Next guess 1500#
((1500/2.3)/1.136)/5.5=104.38# at the pedal, still a very heavy pedal

Trying the same 1500# release force with a different clutch master slave combo, a 1.125" master and same .88" slave give a ratio of 1.278:1 so...
((1500/2.3)/1.278)/5.5=92.78#

I wanted to bounce this off you guys to see if I'm totally crazy, or kinda close with my thinking here. Tomorrow I'll call KEP to see if I can get a better figure, but I'm more worried about my general formula here. Any Input would be a big help.