My other 1303 GL

[ricola]

Why have you got two fan switches Steve?

My CV boots (genuine GKN) only lasted a few days! Right now I've ended up with the race type boots on the outer and big off-road silicone ones at the inners when I have space..

[Wally]

Good job fitting a diff while your in there! I can here my G50 pretty good too, but only always on deceleration. I knew the G50 is a bot noisy from itself as porsche did go pretty far on the insulation on the shifter opening and even the shift rod itself is packed in foam-like material. That was a good clue for me, LOL!

[Steve C]

Hi

I use one fan switch for the dash fan and the other one is for the heater, its under the back seat.

The heater under the back seat is from the rear of a Toyota Troop carrier and blows up the factory heater channels.

When I got the news that the transmission was in good shape I decided that I had some spare cash to buy the Quaife.

I had a Quaife in my 1302 and it worked fine, I know that they are not the ultimate but they don't have any handling vices.

The Porsche gearbox guy was saying that they used a lot of things keep them quiet, dual mass flywheel and blankets over things, apparently the blanket over the transmission used to soak up oil and catch fire

Steve

these are the CV boots I bought from eBay

[dub_crazee]

It's looking really sharp - shame about the gearbox - i feel your pain as i had my 915 rebuilt after doing about 100 miles!

How did you find the wheel alignment? I notice you are running ally arms - and there was a thread not too long ago with a few people having excessive toe out (including me). My spring plates were filed out in the end.

[owdlvr]

Steve, the car and upgrades look great!

Something to consider with the Porsche transmissions is the switch from 6cyl to 4cyl motors. Here in Vancouver we have a Porsche 356 replica manufacturer Intermeccanica. Henry, who owns the business, is a friend and walked up to my car at the first event. "Porsche 5spd?", yep. "Noisy as all hell isn't it." They used to offer a Porsche 901 or G50 option with the VW motors, but now reserve them only for 6cylinder cars. Even with rebuilds and all new parts they were noisy, swap the exact same box into a 6cyl equipped car and they'd be silent. Gotta be something with the harmonics.

Hmmm, this makes me think I should update my thread!

-Dave

[Steve C]

Hi

Interesting comment about the harmonics.

When I worked in a performance VW shop, when we fitted a higher comp, higher performance motor to a customers car its transmission would develop an overrun noise which wasn't there before.

We put this down more savage pulsing on overrun, fitting a sprung centre clutch plate helped.

A 6 cylinder motor would have more even pulsing than a 4 cylinder.

Anyway now I have the peace of mind knowing I'm not grinding my transmission pieces.

I only had my front end aligned, I still have a bit to do to correct the toe out on the rear.

I fitted some offset pivot bolts made by a local drag racer which helped a lot, just need a whisker more.

Steve

The pivot bolts

[dub_crazee]

Ah yes - i remember seeing that - sorry, i had bit of a blonde moment there!

[Steve C]

Hi

Bit of an update, I replaced my cracked 930 CV boots with some eBay ones, great quality.



Some time ago I read post on this forum by Ricola about clocking CVs. After a bit of search I found the information on doing this. You can read more about it here http://www.outfrontmotorsports.com/cv_assembly.htm

I used a plastic windscreen washer bottle as my water to air intercooler reservoir.








It always looked a bit cheap so I bought a aluminium one from eBay and had my friend Westi fit two 3/4 bungs and a two bosses so I could fit a level indicator.

Transmission still has noises but nowhere near as bad as before and it seems to be just one noise now, not a variety of noises. I've decided to keep the extra mountings that I've fitted even if they do transmit noise. At least I know that I’m not slowly grinding the transmission to pieces.

I fitted an extra brake light bulb in tail light housing, just in case and also I've made a move to a more permanent coolant overflow reservoir. I'm using US style tail light lenses.





I was booked in for a dyno on the 18th and to also have a knock module fitted to the Autronic SM4 at the same time.

It was a pretty disappointing day at the dyno, with all the heat build up around radiator because of the lack of airflow, the fuel pump started to make funny noises and cavitate and was making the motor run hairy over 5,000.

So no power figures as such but I did see 169kw on the screen once, the dyno is a very old but a good one but is not hooked up to printers etc like later dynos. I also will need to rethink my fuel pump layout.

I thought that I would post some photos of my 044 pump and surge tank.



Next week I'm going to move the 044 and surge tank to the rear of the car.
For the time being I've changed the surge tank layout a little, I originally had it setup so that fuel returning from the rail would go into the tank and cool a little, I think only relying on the lift pump to fill the surge tank would maybe make the surge tank run out of fuel during in high demand.

I also made some fill panels for my whale tail out of black Perspex and secured them with M5 nutserts and stainless M5 Allen screws.





I'm sorting out ride heights now and just having fun driving it. I'm also setting up the waste gate actuator.






So after I get my fuel issues sorted I will go a for another dyno session.

Steve

[70Turbobug]

Making a lot progress! Looks great! Hope you get the fuel issues sorted out soon!

[NO_H2O]

Looking good.

[chug_A_bug]

Wow just read this from the Start... SWEET build

Hope you get some Video over it when it's all Said an done
I know I'm not only one what would like to See it.

Chris.

[graham]

Hi Steve,been looking through your thread again.How you getting on with the fuel pump set up ? I am doing some research at the moment on best set ups for STI powered bugs with external fuel pumps.Any info advice is appreciated.

Regards Graham

[Steve C]

Hi Graham

I'm going to go in tank 044 now. I'm just collecting parts now.

My friend who gives me some advice in this area and does any tricky welding (he builds fuel, inlet & exhaust system for some of the fastest cars down under) suggested going for an in tank fuel pump.

My reason for moving to a in tank setup is that I have fuel system parts strewn around the front area of the car, I feel if I have everything in one spot I can concentrate on keeping that one spot cool.

I currently have a Carter lift pump on passenger side of the car about where the master cylinder would be on a LHD car, its in the path of the exit air flow from the radiator.

My surge tank and main fuel pump are in boot floor close to the radiator.

Steve

[graham]

Hi Steve.

Thanks for the that I would go in tank as well but I dont want to chop the tank now as its painted and I've bought my external fuel pump and filter.

Thats good thinking on the cooling side of things.I will now concentrate on keeping the heat from my rads away from my fuel system

[Steve C]

Hi Graham

I'm not sure if your motor has it, but my motor ECU controls a variable speed fuel pump controller, I control the 044 with this and lift pump runs at full speed.

Steve