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It will be interesting to see if there is any front tire wear. The parts are headed my way so maybe an update in the next few weeks.
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The new STI motor arrived a few days ago and I couldn't leave it well enough alone. It's actually from an 07 STI, which means it has e-throttle so that will have to get replaced. I started stripping it down looking for dirty secrets, but in looks good on the surface and even the belts were in great shape.
http://i93.photobucket.com/albums/l4...8.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original http://i93.photobucket.com/albums/l4...0.jpg~original I have an 11lb. alu. flywheel and a TY754VBAAA trans on the way, both should be here by next week. I already picked up an OBX diff for the tranny, and even though it's new it still needs to be gone through. With the additional work it's worth the money. I also got a TGV (tumble generator valve) delete kit, so that'll be a weekend project. http://i93.photobucket.com/albums/l4...1.jpg~original In racing news, the 2013 season is finally getting underway. I went to a different series event last weekend that's mainly geared towards muscle cars and they setup a fast course. Unfortunately, my throttle cable snapped 100ft. into my first run and my day was done. I usually have a spare, but didn't have one with me this time. I was pretty bummed until I realized a few things. 1. I trailered the bug there so I didn't need to drive it home. 2. The organizers refunded my entry because I had already done my work assignment and now couldn't drive. 3. If I had to break a part on the car, I'm glad it was one of the cheapest. Earlier in the day, a car lunched it's trans after 3 runs. Having realized my day could have been a lot worse, I started feeling a lot better. There's another autox with NorcalUFO (my usual group) this weekend, so I really want to get out there now :) |
You don't quit do you Will?
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Quote:
I was instructing with HOD in both events in the e36 M3. You're bug is going to kick butt!!! Jason |
Wicked story.
A lot of nice toys in that lot. |
DORIGTT, I'll stop when I'm bored :D BTW, next time you hit sunnyvale vw you should tell the guys there about your ride in my bug, especially Samer. He's the one I bought the golf through.
Volkdent, Do you usually instruct with HOD? That's one of the few groups I haven't run with and I was wondering what they're like? ============= Now on to the good stuff! I started tearing into the STI motor some more to see what I bought, but the more I looked, the more I liked. I pulled off the crank pulley and timing cover to take a look at the timing belt and crank trigger wheel. The timing belt was in great shape and didn't have any cracking or defects much like the accessory belts I pulled off. The trigger wheel is a 36-2-2-2 setup which will make setting up the megasquirt nice and easy since it's a supported tooth profile. http://i93.photobucket.com/albums/l4...2.jpg~original http://i93.photobucket.com/albums/l4...1.jpg~original While I was at it, I pulled the coils and spark plugs, and checked down the bores with a bore-scope. Cylinders and piston tops look great, and the plugs are all iridium tip gapped to .028". Coloration on the plugs was good and there was no debris or flecks that signal detonation. While the plugs were out I put a squirt of oil down the bores and put the motor through a few rotations and everything is smooth. http://i93.photobucket.com/albums/l4...0.jpg~original Got my new (to me) flywheel in this week. It's a gently used Aasco aluminum 11lbs. flywheel that should be perfect for race duty, purchased off one of the nasioc guys. I had to run down to the subaru dealer to grab some flywheel bolts and I'm hoping I can use the vw flywheel tool to help tighten them. http://i93.photobucket.com/albums/l4...c.jpg~original http://i93.photobucket.com/albums/l4...1.jpg~original I spent the day Saturday on this little project. On the newer Subarus they have a small half-butterfly in the intake called the tumble generator valve, or TGV, that helps develop turbulence which keeps fuel droplets suspended in the air and improves low speed driveability. Unfortunately, even when they are wide open they block a lot of airflow, about 50%. I've seen TGV delete manifolds for sale but I figured I could do the work myself and it would be a fun project. First step, pulled the butterflies and shafts from the TGV bodies. I got excited ( a little frustrated ) and had to drill the screws out of the butterflies which seems to be a common problem, but in the effort I forgot to take pics. Here's the TGV body in the vice, and I already removed the divider on the left side with a hacksaw. The TGV only blocks about 65-70% of the opening and you can see the lip the butterfly rests on in the body. http://i93.photobucket.com/albums/l4...5.jpg~original After a little work with a die grinder to smooth the edges here's a nearly finished TGV body, and then both of them together. http://i93.photobucket.com/albums/l4...1.jpg~original http://i93.photobucket.com/albums/l4...1.jpg~original Once they're all cleaned up, you put in some plugs where the throttle shafts were and you're done! All in all it took about 3-4 hours to complete and should make a big difference in flow, especially since I took the time to port match the TGV bodies while I was at it. ================ But wait, there's more! This is like the never ending update. It was also a race weekend! During the week I had replaced the throttle cable, and tweaked the tune to help the cold start a bit. The bug was running much better, and more than a couple folks had noticed at the autox. The course was very tight and technical, which is kind of a bastard thing to do for the first run of the season while folks are rusty. The last few corners were particularly bad with 150 degree turn backs between short sprints. I managed a 50.117 and beat my nemesis by .040 seconds, so close! http://www.youtube.com/watch?v=JDkgARva40Y |
Will, HOD is pretty much all I instruct with now, there is no charge, in fact the last Thunderhill one they paid me $200 to do, so that can't be beat. I'll do Audi and BMW club, but BMW has only a couple of events a year and Audi still has the instructors paying half price, they do have a dedicated instructor run group though, and HOD is kind of a free for all, you get on the track during sessions you're not instructing.
I found this, it happened in your neck of the woods, look out for this one!!! Wrecked Exotics McLaren MP4-12C Jason |
Once I get the bug finished I'll have to take it out to a HOD event :D
That's probably the same mp4-12c that was in the supercar group I came across in the mountains, I know right where that pic was taken. |
Got some more parts in this week. Finally got my transmission, and TY754VBAAA from a ver 5/6 sti.
http://i93.photobucket.com/albums/l4...4.jpg~original http://i93.photobucket.com/albums/l4...7.jpg~original After doing some research the flywheel I picked up is for a modern subaru 6spd which has a larger 228mm clutch disk and beefier pressure plate. It'll work with the trans but not without some modification. There's a bunch of webbing in the bellhousing that will need to be clearanced and i'll have to do lots of test fits with the motor off the stand. http://i93.photobucket.com/albums/l4...4.jpg~original I also got my new megasquirt MS3X ecu this week. I opted for a prebuilt unit with a couple mods, the mapdaddy 4bar dual baro sensor, and the real time clock to time stamp logs. I've temporarily turned the dining room table into a lab and started testing and programming the MS3X. I'm looking into a lot of new features I didn't use/have on the ms2. http://i93.photobucket.com/albums/l4...7.jpg~original http://i93.photobucket.com/albums/l4...c.jpg~original What I've setup so far: waste fire ignition batch fire injection radiator fan control tach output boost control through table blending water injection pump control water injection valve control front axle VSS input transmission output shaft VSS input VSS output to drive speedo traction control with dial-a-slip That's it so far, I'm still configuring everything. I need to get a couple 3 wire potentiometers to use with the adjustable boost and traction control settings. I have the wiring looms ready to go and once the motor and tranny are ready the fun can begin! |
The subaru swap hit the skids while I work on Joy but that doesn't stop me from going out and racing. Event #2 was this past sunday and boy was it nice. I was running in the afternoon, which was pretty hot until the wind picked up, and it was a light crowd thanks to competing events. I didn't have a co-driver this time so the car only did half it's normal amount of runs... which taught me a lot. Oil, tire, and head temps were all down, heads stayed around 375, oil around 150F, and the front tires never got sticky. Without a co-driver I had to wait longer between runs and in that time the front tires lost all temp, which means all grip. I was .9 sec behind my nemesis in the turbo miata which means I was losing about 1 sec from cold tires.
I was going to add a little more front shock to see if it would help stabilize the car under braking, but I was also thinking I might decrease the front camber as well and go back down to -1.5 or -1.3. I'm not getting onto the front tire shoulders at all even with low tire temps, so I can probably dial out some camber. http://www.youtube.com/watch?v=0xYVSlOUVuM |
Event #3 for 2013 and another double points grab. I was running in the afternoon again, and the weather was great. Well, except for the random 40-50mph gusts and large dust devils that wrecked the course a few times. I played with the tire pressures a bit, raising the front to 18psi and the rears to 17psi. That got a lot more grip out of the front than I've had in a while but the rears were now sliding around. She was a handful but with the front sticking better I was able to go faster than before. The fun was short lived, however, since after each run I could hear the exhaust note changing. I had a small exhaust leak, not that big of a deal, but the car started to lose power which was very noticeable off boost. By the end of the group we were pretty much hot-lapping the car, and after my 3rd run I knew something was off. I tried to get a 4th run out of her anyway since I was about 1.5 seconds off top time of day, but halfway through the run the oil light started coming on and I shut her down. I ended up with a 44.4 which should have put me in the top 10 raw times with my 3rd run, and still beat my nemesis by .3 sec which was good for 1st place.
The victory is bittersweet though, and I think the cam might be going as well as the exhaust gasket. There's now a rush to get the sti motor and trans in the bug before the next event in June. I don't think it'll happen by then but we'll see. http://www.youtube.com/watch?v=VjRO2UR_-gQ |
Moar updates!
Despite racing and breaking things, work does actually continue on the car, but I have to apologize for not updating in a timely fashion. I finally got some parts in over the past couple weeks. I got my cast aluminum 2 piece shortened sump, and I finally got my transmission conversion goodies from the land down under. Subarugears makes a flip ring & pinion kit for the 5sp and I'm way impressed with the quality. Besides the R&P the kit comes with a setup tool, center diff spool, plug for the shortened center diff housing, output shafts (mine are type2/porsche pattern), a machined shift knob and a couple of stickers for good measure. http://i93.photobucket.com/albums/l4...6.jpg~original This week I've been working on the transmission and tearing it down to see what I bought. It's a TY754VBAAA from a 99-01 ver. 5/6 STI and supposedly one of the strongest 5sp built, or so I've read. It came apart in short order, found lots of corrosion on the through bolts that clamp the transmission together, not sure if that's normal galvanic corrosion or what. Before tear down I checked the shift action and it was still tight and notchy which gave me hope. http://i93.photobucket.com/albums/l4...5.jpg~original Looking at the gear stacks, they didn't look bad at all. First and second syncros got beat up pretty good but I've definitely seen worse. I tried to get close up pictures of the synchros but dropped my camera instead. :P I never did take the pics and now the stacks are off getting rebuilt with the new pinion shaft. Another quick project that didn't get photos is rebuilding the OBX lsd. I got the rbryant kit, tore apart the OBX expecting to resurface it and was pleasantly surprised. The OBX wasn't perfect but was very serviceable in the shape I received it. The bolts and washers were replaced anyway as a precaution and everything bolted back together just like it should. http://i93.photobucket.com/albums/l4...7.jpg~original Last night I modified the case to accept the flipped differential. This is going to look so wrong to subaru guys :) I used a grinding disc to take care of most of it and I have some flap discs that I'll use to smooth things out later. I accidentally ground through the case on one of the bolt holes so that will have to be patched up later. For now the diff fits and spins easily with no contact and plenty on clearance. http://i93.photobucket.com/albums/l4...1.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original http://i93.photobucket.com/albums/l4...a.jpg~original Next on my to do list is to clearance the bell housing for the sti clutch parts. I have an Exedy stage 1 STI pressure plate and disk on the way and once they are here I can check for interference. |
Big holiday weekend means lots of car work! I started the weekend by working on the other project first and finishing up the rear suspension. I finished the weekend by pulling the motor out of the race bug.
First up, got my gear stacks back with a collection of new gaskets, seals and shims. http://i93.photobucket.com/albums/l4...f.jpg~original Also got the new pressure plate and clutch, Exedy stage 1 http://i93.photobucket.com/albums/l4...5.jpg~original http://i93.photobucket.com/albums/l4...8.jpg~original Lastly I got some wiring components in, 100' of 8 colors, 14ga, chemical and heat resistant wire, and a couple of 22pin bulkhead connectors. http://i93.photobucket.com/albums/l4...8.jpg~original http://i93.photobucket.com/albums/l4...d.jpg~original "I should have this outta here by dinner!" Nope. Drained 2.5 gallons of oil from the tank, then some from the motor, then some from the lines... and there was still oil dripping from here and there. I didn't get a picture of it but the header had separated at the slip fit. That would cause all the symptoms I was having right before I trailered it. Still going to check the lift at the valves to be certain. http://i93.photobucket.com/albums/l4...f.jpg~original http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...6.jpg~original It took a while to get the header, intake plumbing, and oil lines out of the way. Besides where the header separated there was only a bit of an exhaust leak on #4 and everything else had sealed tight. Sunday, I started pulling everything else to get the motor out and on the stand before BBQ time. Fuel lines out, and manifolds off, and the motor pops out nice and easy. I wheeled the EJ25 out of the garage for some good comparison shots before cleaning up. http://i93.photobucket.com/albums/l4...0.jpg~original http://i93.photobucket.com/albums/l4...5.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original http://i93.photobucket.com/albums/l4...0.jpg~original http://i93.photobucket.com/albums/l4...3.jpg~original Transmission comes out next then it's time to pull the seats and the oil tank. The subaru trans needs to be finished up in the coming days, and wiring is also on the horizon, which will be a tedious job, but should be easier with the wiring diagram I've been working on. |
Maybe get some A/B weights of those things while you have apples and apples to compare?
Jason |
I wish I had a scale that could measure them, but I can already say that the type 1 is easier to move around with a couple guys than the ej25. I'm hoping the ej25 gets a little lighter once it's drained (it shipped full of oil) and the header/turbo come off, but I don't know if that will even things out.
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Got some more work done on the car this weekend, even though it was 95F+ in the driveway on saturday. I spent most of saturday inside designing the new wiring harness and reading up on the MS3X VVT control. I want to see about using that for the ej25, but it adds 10 wires to the engine harness. Once it cooled off outside I started trimming down the center diff housing for the subaru trans. The guys at subarugears put an awesome video up on youtube that shows where to cut.
http://www.youtube.com/watch?v=RXEUSVSpGHg On sunday I headed over the Ambryn's place to get some help welding up the center diff housing, and to meet up with Ron who has a subaru swapped porsche 912. The 3 of us are at different stages in our swaps and so far have picked eachother's brains quite a bit. After chatting a bit (hours) Ron headed home and Ambryn and I got to work, but really Ambryn worked and I supervised. Cleaning up some shoddy grinding that *somebody* did and making it look pretty http://i93.photobucket.com/albums/l4...c.jpg~original http://i93.photobucket.com/albums/l4...9.jpg~original Looks much better after removing what's left of the freeze plug boss http://i93.photobucket.com/albums/l4...4.jpg~original Ambryn welded up the subaplug and the leftover holes. He blasted it afterwards to check for pin holes and clean it up. http://i93.photobucket.com/albums/l4...c.jpg~original I treated Ambryn to lunch and a great little taqueria (a staple food for me) and headed home to get a little more work done. Sean, my tire warmer/co-driver, came up to give me a hand for a bit. We pulled the seats out to make getting into the back easier to pull engine/ecu wiring and oil lines. http://i93.photobucket.com/albums/l4...c.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original While I was at it I pulled the shift coupler free and Sean removed the trans and trans strap kit from the back. http://i93.photobucket.com/albums/l4...c.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original I've been going over cage re-design ideas in my head a lot recently. I haven't been happy with the cage because it cuts into the driver space too much and it needs to be closer to the A/B pillars. I also want to eliminate the rear package tray so the firewall slopes from the bottom of the rear window to just above the transmission nosecone. That will give more room for the turbo and oil cooler underneath but I'll have to modify the rear cage stays. I'm contemplating chopping the cage forward of the main hoop, then shortening the rear cage stays to match the new firewall, and staying with a 4 point until a new cage can be welded in. |
Progress looks great! How nice that the three of you can get together and discuss different ideas in person. Very lucky on that count.
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Things have slowed down a bit, but progress continues. Work has been killing me lately so I spent last weekend out camping near Yosemite with a bunch of friends and it was a great way to unwind. I learned a valuable lesson about drinking at 8000', not too much and not too fast.
I got some new parts in that will go on the car soon. Back in March or so I put an order in for these 935-style adjustable spring plates and they finally came in. They are 7075-T6 aluminum, with a burly M20 heim for the pivot, and grade 12.8 hardware throughout. Thanks Alex! http://i93.photobucket.com/albums/l4...b.jpg~original http://i93.photobucket.com/albums/l4...c.jpg~original They replace the spring plates forward of the rear disk in this picture. http://i93.photobucket.com/albums/l4...3.jpg~original I bolted up the rear motor mount/adapter from subarugears.com since I was worried it might not clear the mendeola rear suspension brace. It's a tight fit but it works. http://i93.photobucket.com/albums/l4...7.jpg~original http://i93.photobucket.com/albums/l4...a.jpg~original Speaking of Mendeola, I saw that they offered their own mounts for the subaru swaps, so I ordered their front mount and shift rod coupler. Top notch parts from great guys! http://i93.photobucket.com/albums/l4...4.jpg~original Racing season is still in full swing but the car is on blocks, what to do? I called my friend (and closest competitor/nemesis) Ian to see if I could co-drive his car. Ian has an OSP '99 miata with the Flyin' Miata catalog thrown at it and it's a fast car, faster and better setup than my beetle. Well, I was able to best Ian in his own car by 1.23 seconds, and drive it to a 7th overall in raw time, and 4th in pax. It's not all bad, I did pay his entry, and he had a datalogger going so he can compare our runs to learn from the whole thing. I learned quite a bit as well, like how wonderful an lsd is and what lack of understeer feels like on turn-in. I'm pretty jealous I have to say, it's a sweet ride. UFO 2013 Autox #4 07-9-13 - YouTube |
Good to see things are coming along, I've been watching your progress for some time as we seem to have the same goals in mind. So when are you gonna bite the bullet and put the Mendeola S2 suspension under your car? I'd say it would probably help reduce if not almost eliminate the understeer you're experiencing now. I can't wait to see how your car does with the new tranny and powerplant, keep up the good work.
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Mr_Zed_ZX20: I would love to throw the S2 suspension under the car but it's still a bit cost prohibitive, about the same cost as the entire subaru swap. The front suspension would help a lot but I'm learning that many of my handling issues are mostly setup related. The 1302/1302 suspension is capable of much more than folks give it credit for and I'm still trying to get the most out of it (nevermind the porsche updates, its still struts up front and semi-trailing arm rear).
Now that being said, I may end up with the S2 suspension parts on my street car :lmao: |
Yeah, the S2 setup is a bit spendy. I bought mine last year with the money I had set aside for my ex's engagement ring after she broke up with me, lol. Needless to say, I think the S2 was a better choice (less complaining, etc). Unfortunately, its STILL sitting in my garage waiting for me to install it along with my Boxster S brakes. If all goes well I'll be starting on it in a few weeks.
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Overdue update:
I've been crazy busy with vacations and work since the end of June. I was either out of town or running around with friends who were in town. I was able to work on the trans here and there, but made it more difficult than it needed to be. When I got the aluminum Aasco flywheel I didn't know there was a difference in the STI and WRX parts. When I did some digging I saw that you could clearance the bell housing to make it work. Not really.... http://i93.photobucket.com/albums/l4...1.jpg~original http://i93.photobucket.com/albums/l4...2.jpg~original http://i93.photobucket.com/albums/l4...8.jpg~original I trimmed the webbing around the bell housing to clear the flywheel and clutch and did my first test fit. the bottom inspection opening isn't big enough and the clutch fork pivot is too close. It clears on one side but as I ground a hole in the bell housing near the starter boss to make it fit on the other side I saw it wasn't going to work. Ambryn came to my rescue and welded up the hole for me, but I didn't get any good pics of it before the repair work. I had to grind the starter boss flat again, and profile the area where the clutch fork pivot shaft plug goes in. I needed to re-tap the hole as well since the threads melted a bit from the filler work. http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original http://i93.photobucket.com/albums/l4...e.jpg~original Now with the trans cleaned up I can put it together |
Things went together easy enough when I remembered to include things like the vss drive gear and shaft :P After cleaning the case halves to remove all the aluminum dust I dropped the driven shaft in to do the shim measurement. You put it in without shims first and use the subarugears tool to find out how many shims to add.
http://i93.photobucket.com/albums/l4...e.jpg~original http://i93.photobucket.com/albums/l4...8.jpg~original http://i93.photobucket.com/albums/l4...2.jpg~original The pinion depth shims are cheap so I ordered a bunch in different thicknesses ahead of time to have them on hand since every dealership I talked to didn't keep any in stock. Next I turned to the bearing races and seals for the differential. Just mark then loosen the adjustment cups on either side, the bearing will probably fall out while you are doing this. Replace the o-ring and the axle seal, make sure that the seals are the the "wrong" side. Left goes on the right and vise versa, that way the oil grooves are in the correct orientation for the reversed R&P. http://i93.photobucket.com/albums/l4...3.jpg~original http://i93.photobucket.com/albums/l4...3.jpg~original http://i93.photobucket.com/albums/l4...9.jpg~original Quick note about the differential. I got an OBX LSD and replaced the washers and bolts "just in case". Before i put the ring gear on, I tested the output shafts and they were too tight to go on. I used a dremel to run the grooves on the diff splines until I could get the output shafts on. This is fairly common with OBX diffs it seems, when I tried the output shafts on the stock diff they slip on nice and easy. Time to put it all mostly together. Put the case halves together and tighten it all up, but leave the nose cone/center diff housing off. Those differential bearing cups need to be adjusted now and rather than go through the pics (which I was too busy to take :P ) you can watch the subarugears video which was hugely helpful. http://www.youtube.com/watch?v=xSWPKmA09ng Once I did that, I took it all apart, greased up the ring gear and put it all back together again to check the pattern. You don't have to do this but I was really curious, and it came out fine. http://i93.photobucket.com/albums/l4...e.jpg~original Let's talk about RTV. Let's talk about you and me. Let's talk about all the good things but mostly bad things that you see. Let's talk about sealant. Let's talk about sealant... Just a little line and spread it out with your finger, it should be a very thin coating meant to fill gaps. I'm tired of seeing half a tube of liquid gasket, RTV, or permabond used to seal surfaces. http://i93.photobucket.com/albums/l4...9.jpg~original http://i93.photobucket.com/albums/l4...1.jpg~original I got all excited and forgot to get a good shot before the nose cone and axle stubs went on so BAM! built transmission ready for install. I did the common trans fluid mix of 1qt. motul 75w90 and 3 qt. redline shockproof synthetic gear oil, which gets great reviews on nasioc. http://i93.photobucket.com/albums/l4...b.jpg~original |
I mentioned earlier about difficulties with the STI flywheel & pressure plate. I went and got a whole new WRX setup to use on the car instead but took some shots side by side while I had all the parts.
Right side: STI Aasco 11.5 lb aluminum flywheel, Exedy 15803 stage 1 clutch and pressure plate Left side: WRX ACT 9.5 lb chromoly flywheel, Exedy 15802 stage 1 clutch and pressure plate http://i93.photobucket.com/albums/l4...4.jpg~original http://i93.photobucket.com/albums/l4...3.jpg~original http://i93.photobucket.com/albums/l4...e.jpg~original http://i93.photobucket.com/albums/l4...3.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original Basically the WRX parts are the ones you should be using with the 5sp. Your life will be a lot easier if you do. For a street bug using this swap I'd go with a heavier 12-15lb. flywheel, but in the race bug lighter is better. The WRX stuff is a bit smaller in diameter, which reminds me of the bug vs bus flywheel/clutch/pressure plate questions when running my old type 4 motor. |
Hi
Thanks for the write up. How good is having gearbox split in 1/2 so you can more easily check the bell housing clearance. Steve |
No kidding right? This week the first test fit of motor an transmission should happen, as well as some more clean up on the body, old wiring, and plumbing.
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So I WAS going to try and test fit the motor and trans but sent the oil pan off to get modified instead. The awesome, bug@5speed pan doesn't clear the stock subaru mounts, so I need to run a shortened stock sump. There's no shortage of work to be done though so I continued stripping the bug. I finished pulling the fuel system, and fuel cell out of the car to make room for the radiator. I got everything out and started cutting before I realized I hadn't taken any pics :P
http://i93.photobucket.com/albums/l4...d.jpg~original The radiator is for a 95 rx7 turbo but it fits perfectly in the bug. The bottom mounts attach to a lower radiator support welded to the forward body mount points. The top of the radiator is braced to the body on either side, and it's pretty sturdy. You can also see the new fuel tank that is loosely resting in the stock location. It's a 15 gallon RCI tank, and I wish there was a better place to put it, but for now it has to sit up high http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...a.jpg~original http://i93.photobucket.com/albums/l4...3.jpg~original As I was test fitting everything, I grabbed the air/water intercooler setup and started placing parts. The heat exchanger is an upgraded Ford Lightning part, water pump also comes from the Lightning, and the tank is a simple 1 gallon cell. The heat exchanger fit perfectly behind the stock grill opening, but finding a good spot for the tank and pump was a bit harder. I' worried that filling the area behind the radiator will kill the air flow, and I don't want to heat soat the water tank. Between the tank, pump, heat exchanger and lines, the extra weight adds up. I've been thinking about doing an air/air setup out back but now it'll probably get serious consideration. http://i93.photobucket.com/albums/l4...a.jpg~original After a bit of a break I started working on wiring. I pulled out the race dash and switch gear, and started trimming back the harness. I wasn't happy with the location and routing of the stock harness, so with all the new parts I'm re-doing the wiring again to clean it up and simplify the circuits. I'm also going to go with a more modern fuse/relay box relocated to the glove box area for easy reach. I'm going to go back to the stock dash, and use a digital dash in the stock location which should be a little easier on the eyes. http://i93.photobucket.com/albums/l4...e.jpg~original |
Got my shortened pan and pickup back from Jeff who did an awesome job. Got them bolted onto the motor so I can get a trial fit of the motor and trans in the next few days.
http://i93.photobucket.com/albums/l4...2.jpg~original http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...1.jpg~original http://i93.photobucket.com/albums/l4...0.jpg~original |
Hi
I hope you don't suffer oil surge with that sump mod, I had wings fitted to mine. Steve http://i1184.photobucket.com/albums/...p.jpg~original |
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Hi
Just noticed that my sump has a more elaborate windage tray, maybe because its a STI or just a different model motor. Steve |
Mine is US spec Sti and I've noticed that the pans and pickups are different. The Sti pan is more narrow than the wrx and forrester pans. If you use equal length headers they won't fit if you have kickouts or a non-Sti pan. I'm going to supplement the oil system with an Accusump until I get a dry sump pan and pump. The section that was chopped was so smal l it only lost a quart or less of storage. When I refill the motor I'll mark the new high point on the dip stick and be good for the moment.
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http://www.accusump.com/images/main_banner.jpg
I'm also running the accusump in my shortened sump arragement. Need more $$ for drysump! |
Hi
The Accusump is a good plan, I was going to fit one to my motor, I've kept it for an Oxy Boxer I'm building for my sons car. I've only run my car hard on a track for few laps but I suffered no surge with my sump, talking to Subaru owners they often have oil surge issues. I'm probably not getting the same Gs as them or yourself Steve |
Yeah, oil starvation is a big problem for subaru motors and they spin bearings very easily when the pickup goes dry. I know 2 guys locally with subaru swaps, a buggy and a beetle. Both of them have spun bearings more than once under autox conditions. I figure an accusump is cheap insurance, but a dry sump is the real fix.
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Time attack beetle
Hi Humble
I am watching your build with interest. I am planning my engine and gearbox swap and slowly collecting parts.I was planning on shortening my sump and extending it forward a bit. Ricola has done this and the Idea is his, so I cant take any credit for it, but in addition to this he has added one of these http://www.rogerclarkmotorsport.co.u...ctID=3147.this This looks like a good insurance against oil surge. All the best Graham |
Two steps forward, three steps back, pretty frustrating weekend, but important update none the less.
I started by getting the motor ready, bolting on the flywheel, and clutch assembly. This job was made easier thanks to the aircooled vw flywheel lock, handy little thing. http://i93.photobucket.com/albums/l4...4.jpg~original http://i93.photobucket.com/albums/l4...d.jpg~original While I was at it I did some more body mods to make sure I had enough clearance for the motor and turbo. I removed the sealing tin from the rear package tray, and cleaned up the sides to match. http://i93.photobucket.com/albums/l4...0.jpg~original http://i93.photobucket.com/albums/l4...4.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original Next I got the motor and trans together nice and easy and tried to get it into the car. Firstly, the output stubs had to come off to get the trans in the right position. Then it became obvious the turbo wouldn't clear the package tray. Try as we might I was about an inch from getting the new motor mount bolts in. Finally I pulled the trans off the motor so I could manhandle it into place and see what the problem was http://i93.photobucket.com/albums/l4...8.jpg~original I'm going to come out and say it right away, the subaru trans will not fit the bug without modifying the body. With the medeola motor mount in the lowest position, the top of the bell housing just clears the package tray, BUT the clutch fork does not. Also, the new nose cone/old center diff housing contacts the body above the torsion bar tube. You need to modify this area like you did for the old 901/914 trans swap. http://i93.photobucket.com/albums/l4...7.jpg~original http://i93.photobucket.com/albums/l4...4.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original http://i93.photobucket.com/albums/l4...8.jpg~original I was hoping I wouldn't have to do any body work but it's necessary. I'm going to use this as an opportunity to re-do the cage as well as prototype a mod I've had in my head for a while. The idea is to take the rear package tray and make a 45* angle from the bottom of the back window to the floor above the transmission. To make this happen I have to sacrifice the front of the roll cage to keep the main hoop/rear stays, so out came the cutting tools and the cage. http://i93.photobucket.com/albums/l4...8.jpg~original http://i93.photobucket.com/albums/l4...f.jpg~original The rear cage stays will have the plates cut off and the legs shortened to meet the new raised floor. It will be cleaned up and have what's left of the old front section removed. http://i93.photobucket.com/albums/l4...3.jpg~original A very empty beetle... http://i93.photobucket.com/albums/l4...b.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original On a side note, I'm drawing up the new wiring plans, and I want to switch to a digital dash. I've been looking at the Aim MXL Strada, Race Technology Dash2 Pro, and the Racepak IQ3 and want to find folks who have used them. Of the 3, the MXL Strada is the only one with official support for the megasquirt MS3 on CAN bus, the other 2 are CAN capable but don't support MS3 on CAN bus, only serial. Once you factor in logging and camera control the Dash2 Pro and IQ3 start looking better due to price. Any info would be helpful. |
Really inspiring build.
I see you have chosen the extended Subaflanges. What driveshafts will you use? I can not find any that fit when you have extended fitted. |
I haven't measured yet, but I'm sure there's something out there that will fit. The wide turbo arms give me a bit more room, so I'm guessing I'll need something around 17" +/- 1". I'm not opposed to custom length axles from sway-a-way but I want to find an off the shelf part if possible.
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It was a rough week, but I hunkered down and soldiered on. Found out a good friend and former co-driver passed away very suddenly a week ago. He was pretty young at 29, and I didn't even know he was sick, but he had late stage liver cancer. Biehruz was the kindest and most competitive guy I know, he will be dearly missed.
Worked on the bug off and on but got a lot done over the weekend. It seemed like I was spinning my wheels, but hopefully now I'm over the hump. The rear package try was ready to be modded so I started there. I cut along the sides and in the corner so I could fold the flaps up to meet in the middle. http://i93.photobucket.com/albums/l4...3.jpg~original http://i93.photobucket.com/albums/l4...d.jpg~original I trimmed up the sheet metal and I'll make a new floor later. You can see the new floor brace I started on that may also support the accusump later. I started to pull the rear suspension apart because it needed to come out to get the front transmission mount in. http://i93.photobucket.com/albums/l4...7.jpg~original With the floor trimmed up it was time to try and fit the motor again. it's a bit of chicken and egg when it comes to the front trans mount. You can't place it without having the motor/trans together, but its a pain to get the motor/trans into place as a whole unit. Eventually I got them into the car and bolted the motor mount in using the lowest setting. Just eyeballing it now looks like the cross pipe for the header sits about where the old turbo was mounted. http://i93.photobucket.com/albums/l4...e.jpg~original http://i93.photobucket.com/albums/l4...9.jpg~original I had to cut a little flap to clear the nose of the trans. After the fact I realized it might fit if I had ground down the rib on top but it still would have been a tight fit. Of course I failed to notice the brake line for the rear was right against the body so I cut right through it :P http://i93.photobucket.com/albums/l4...6.jpg~original http://i93.photobucket.com/albums/l4...b.jpg~original Now it was time to completely remove the rear trailing arms so I could locate and drill the holes for the forward trans mount. It was such a pain in the ass to drill the holes, my arms were killing me by the time I was done. I needed to pull the trailing arms off anyway to upgrade the spring plate and swap out the driver's side trailing arm to match the passenger side. http://i93.photobucket.com/albums/l4...8.jpg~original http://i93.photobucket.com/albums/l4...8.jpg~original I quick comparison between the old '87 944 turbo trailing arm (bottom) and the new '90 944 S2 arm (top). The big differences being the elimination of the bump stop pad and the new arm is ready for a wheel speed sensor. There is a different stub axle with teeth around the cv cup if you're curious. http://i93.photobucket.com/albums/l4...3.jpg~original Passenger side bolted in loosely for test fit of the new 935-style adjustable spring plate. Seriously awesome part, thanks Alex! http://i93.photobucket.com/albums/l4...c.jpg~original http://i93.photobucket.com/albums/l4...6.jpg~original That's about it for now. It doesn't seem like much but for each thing I had to do something else to get it ready. Hopefully now it goes a little smoother and there won't be as many problems. |
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