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  #46  
Old April 18th 2004, 09:21
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Hey Alan,

yeah, I'm not too happy with the current setup. That's why I started with the shroud and not the heatshield. I'll do some searching in the plumming departement to see if I can find a couple 90 degree bends that will fit the throttle body so I can move the box. Once the MAF sensor is in I can mock up the complete air intake system and do a better 'planning'

Panel, so you are getting a custom programmed ECU ? Who is doing this for you ?

Rob.
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  #47  
Old April 18th 2004, 09:35
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Rob, It's not really all that "custom". It is a Delphi unit made for GM's marine division and they have basic maps depending on which engine (4cyl, 6cyl, 8cyl). It's something my buddy in Cali "farms out", not by choice though, Delphi is real picky about the base map software and the blank ECU's and there is a high intial buy-in. The ECU map is tweaked or optimized a little but is basically stock. An example... a stock Cavalier with the smog equipped Eco is about 140hp. The stripped down version I'm using makes 170hp.

If I get to build a turbo engine next year, I'll probably ditch the Delphi and go with the Accel DFI. Some serious coin $$, but I'll have to run a different ignition and injectors for the turbo so it's nessecary...
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  #48  
Old May 16th 2004, 20:31
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Made a little progress.... see:
http://www.vanbran.com/bug/conversion4.htm

Rob.
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  #49  
Old May 16th 2004, 21:01
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Wow that wiring looks scary... You are a braver man than I am.


You might want try some tin foil over the styrofoam.??? It might work...
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  #50  
Old May 16th 2004, 21:42
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Nice! Progress is always good!

That wiring harness makes me shudder...
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  #51  
Old May 17th 2004, 09:45
ajracer ajracer is offline
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HELP is on the way !

Rob:

Just came across your "styrofoam" problem and there is a little trick
you must do in order to be able to fiberglass over the foam. The chemical
attacks the styrofoam as you have "nicely" displayed. I have been really
busy this part five days with organizing a major convention for our church
group at the Metro Trotonto Convention Centre so I need to locate the
"Trick" and then I will reply. BETTER yet please call me or e-mail me in 24
hours and I should be able to handle this for you. So don't panic and work
on something else.

Allan


PS> My Super should be on the road in a couple weeks !
Question: When is or was the May club meeting ?
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  #52  
Old May 17th 2004, 11:21
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Hey Allan,

The meet is tomorrow night.
Let me know if you can make it, maybe you can get me the info then.
Although I am now also considering using wood for the template.

Rob.
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  #53  
Old May 17th 2004, 13:16
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Rob,
Just a thought about your fiberglassing problems. There are two ways that I know of to stop the "melting" issue. (which is caused by the way by the Styrene in the resin. Styrene, I've been told, is also the main component of most foams (styrofoam?)
1: Cover the foam with regular white glue, you'll probably need to give it a couple of coats, and make sure all the pinholes in the glue are well filled. Then just fiberglass over the whole thing like you normally would. You may want to touch the hardened glue with a little sandpaper to roughen it up (may help the FG to "stick")
2: Use a Epoxy resin which will not contain Styrene. Many "Marine Grade" resins are Epoxies.

Just as a note of interest, you could use the styrofoam sheets that are used to insulate basements/houses. If you made a solid blank of the entire shape you where trying to build, you could then FG over it and "melt" the foam blank out of the middle with acetone (which will not harm cured fiberglass). I've seen it done when making prototype kayaks. Oh, and the "sludge" that the foam melts into should be sealed into a can (large paint can, etc.) and can be disposed of as hazardous household waste.

Hope this helps!

Cheers,
Dave
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  #54  
Old May 20th 2004, 09:33
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Exclamation

Rob, about the alternator question from the other night. I looked up a GM three wire alternator and it goes like:
A terminal: excitor wire from ignition switch. On two seperate wiring diagrams the wire is classified as 'resistor wire'. The only reference that I could find for it was a voltage less than 9V and greater than 2V.
B terminal: thin (red) wire feeds back to the starter and attaches to the same terminal as the large + wire (see below)
+ terminal:feeds back to the starter and attaches to the large power terminal.

Well hope that helps somewhat... Maybe Crappy Tire would have a single wire alternator? It would just be sooooo much easier

Cheers,
Dave

ps: thanks again for the seat stops. One more thing off my list!!
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  #55  
Old May 31st 2004, 13:37
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Thanks for all the help and suggestions guys !

I decided to put the FibreGlass project on hold for now and focus on other areas.
See the website for more details, but basically I finished the wiring harness (I hope), installed the exhaust manifold, and got her off the ramps to see what kind of clearance I have (not much)



Oh yeah, I also installed my high-tech, light weight race seat and had my driver check it out


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  #56  
Old June 2nd 2004, 09:01
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Hi Rob,

Nice and interesting project you're doing there!
About the styrofoam and fiberglass problems. One thing you can do is to cover the styrofoam with self adjesive aluminum tape. This tape is typically used on home and commercial ductwork, a little heaver than your typical aluminum "foil". Just cover the form you want to fiberglass with it, effectively sealing the foam. I believe you can also wax the tape, allowig the 'glass to be removed once cured.
Another option is to use polyurethane foam - pretty sure it's the stuff they make surfboards from and I don't belive it is attacked by typical resins used in fiberglass work (polyester, vinylester or epoxy). They've been fiberglassing over foams for decades, key is using the right kind of foam.

Jeff
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  #57  
Old June 2nd 2004, 13:29
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Rob, things are looking good. I moved the firewall forward about 14" on mine. Right up to the back of the rear seat. Gave me lots of room. Mine is a 2.0 twin turbo in a 56 Oval.

Ernie
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  #58  
Old June 2nd 2004, 14:19
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Ernie,

I'd be very interested in seeing pics. Do you have a website or pics you an email me ?

Also, what are you using for ECU, the stock one ? If so, what are you using for an OBDII reader ?

Thanks,

Rob.
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  #59  
Old June 3rd 2004, 11:34
junkyard oval junkyard oval is offline
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Rob
Photos are at http://photo.starblvd.net/junkyardoval

If you can get it to work. The site has been very slow.

I am using the stock ecu and wires. I have a friend who has done the conversion on two VW Vanagons with the 2.2 Subaru engine. He is doing my wiring for me. He also made the adaptor plate and lots of other parts. Nice friend. I hope to have mine on the street this summer. I have used 944 Porsche disk brakes and 16" wheels. A 901 five speed trans and sway bars from a Mazada Miata.

Ernie
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  #60  
Old June 3rd 2004, 17:45
beesquad711 beesquad711 is offline
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The more I read this thread, the more I want to do this conversion. The deciding factor...MONEY!!. How much are you into this (cost-wise) for the engine and conversion alone (parts essential for the conversion: motor, trans adapter, etc.)? The question is for anyone who has done the WRX swap. Thank guys. Oh yeah and the car looks great!!
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