Sweetness!!!

Weekend update, feels like i'm spinning my wheels...

Spent friday removing the fan shroud and alternator off the old motor to stick the alternator in the race motor. Tore it all down and put the welded fan on it as well as the aluminum back plate. Now that the alternator assembly was together I could properly clearance the DTM shroud... which took the rest of the day. A lot of trimming and fitting and trimming and fitting. Another project for friday was cutting new push rods since the last set was a bit short and I didn't want to pull any rocker block shims.

Saturday I pulled the old motor and tranny. Once those were out I tried fitting the 091 and adapter kit but I needed to clearance the frame horns. I ground down the inside seam so it was flush and seam welded them. I didn't want to cut into the body like I did with the last car and the adapter kit had the wrong kind of nose cone mount for a 73+ pan. While thinking about a front mount design I pulled the old gas tank out and put together the first fuel line for the motor. For peace of mind I set the front race rim (18x8.5 et50) in place to check clearance and it's fine all around.

http://i93.photobucket.com/albums/l4...7.jpg~original

http://i93.photobucket.com/albums/l4...5.jpg~original

Sunday after a little checking on the web I found the 10 degree mount for baja bugs. I don't think they are made anymore but I could make one just as easily. A couple peices of scrap angle iron and a cardboard template later I had a nose cone mount. This mount puts the shift shaft through the stock location so I can use the stock shift rod and coupler. The only thing that worries me is the tight fit for the clutch and throttle cables. For fun and to kind of wind down after 3 more days in the sun I fitted up the rear spoiler. It's an APR gt200 knock-off but it should still get the job done. It's 61 inches (155cm) across and reaches about the middle of the rear fenders. To mount it I turned the stanchions around backward and made an extension for the rear wing mounts. Its funny but it almost looks like it was supposed to be that way.

http://i93.photobucket.com/albums/l4...6.jpg~original

http://i93.photobucket.com/albums/l4...1.jpg~original

love that rims, and that is wide, very nice humble.

Overdue update

I've got a lot done since my last update but the pics are in my friend's camera :P

At any rate the motor is finally in the car and we've started plumbing and wiring. Got the fuel level sender installed in the fuel tank and the fuel tank in place. Fiddled the the location of the fuel pump a bit but I think I'll leave it next to the fuel cell in the spare tire well to keep the plumbing simple. I ran out of room in the engine bay so I'll have to put the coil on the inside of the car and run a fire wall pass-through. The oil cooler mounting will be creative since the cup brace is in the way. I think I'll hang it from some aluminum flat stock I've got. I've also been fiddling with the oil filter location trying to find a spot for it that does interfere with something else. Looks like it might end up next to the passenger side rear wheel but it maight be a tight fit with race rubber. We just finished painting the cage and it looks a bit better now and started stripping the rattle-can-red paint job to find okay-ish saturn yellow underneath. Also switched tires from my fuchs to a flat blacked set of phone dials I had so I could restore the fuchs. The phone dials look great on the car and will really complete the look once the bug is repainted.

Here's a couple pics I have so far, I'll try to get more later.

Motor in and ready to rock, only a little bit of plumbing needed to make it run.
http://i93.photobucket.com/albums/l4...5.jpg~original

Painted cage and a dash panel I picked up at the summit store when I cruised through Reno Nevada.
http://i93.photobucket.com/albums/l4...6.jpg~original

Fuel cell and pump set in place. I still need to final mount them now that I know where they're going.
http://i93.photobucket.com/albums/l4...8.jpg~original

I'm so impressed with your car, I've met spider bait at the nag meets a couple of times...

nice setup humble....what motor is that? turbo sum more!!

kuleinc: what were you driving at the NAG meet? At the next one you should come up and say hi :)

BulletBug: The motor build is here but basically it's a fuel injected 2165cc, that's been dry sumped and turboed. :D

I didn't see your car last friday... I drive a primered 73 super beetle, with HID headlights, and my brother in law drives a skittle blue standard 72 beetle. We're having a bit of bad luck with his motor and cams going flat and eating lifters, we're on our second time around on it, and I think its flat again, he basically has the same motor as I do, except with an engle 120 instead of 110, we'll find out for sure tomorrow...

I got to the meet last friday late, I was the guy with one headlight and one taillight out....

I wasn't able to make it out last friday unfortunately, I was stuck at work until 8 so I just headed home (60 hour week for me). That sucks about the motor though, is he running dual springs or HD singles?

Are you close enough to Santa Clara/Cupertino to hit the BLTN meets on thursdays at Lawrence Expy and Stevens Creek? I'm usually there every week.

I'm gunna have to make a trek to one of the NAG meets, just need things to settle down around here. I have a 1 week old son now, so I'm busy being dad at the moment!

Jason

Yeah, I just saw that, congrats again! Once he's a little older you should definitely drag him out to nag, there's a bunch of vw rugrats now :)

We live in the town just north of the NAG meets, I do work in Fremont though... Maybe one Thursday after work I'll head out there. He's running dual springs, I think we got it sorted out now though, he kept bending pushrods too, had to replace a couple of tubes. Now we're working out on the fuel side of the motor, his electric fuel pump has turned his carbs into fuel injectors lol, its gettin there though, its super smooth sounding...

Too much time between updates, that's what I'd be thinking if I were following this thread :)

Things are progressing slowly but surely. It's getting closer to starting a little bit at a time. Got the sump tank mounted finally, along with the tank for the water injection system. I mounted the water injection controller on the rollbar on the driver's side to make it a little more accessible. Ran the water and vacuum line for the water injection system as well, they join the bundle that runs to the engine bay. I went with the #2 nozzle at the top of the T where the intake splits, should be good for 250-400hp.

For the sump tank mount I sandwiched adel clamps with 2 strips of 1/8" aluminum flat stock. It came out pretty sturdy and once the tank clamps are tightened there won't be any wiggle room.

http://i93.photobucket.com/albums/l4...6.jpg~original

http://i93.photobucket.com/albums/l4...7.jpg~original

http://i93.photobucket.com/albums/l4...8.jpg~original

And here's a shot where the oil filters ended up. It's an unused mount for a Z-bar setup, so I added another bolt and put the filters behind the tire. There's about an inch or so clearance with the race tires in place.

http://i93.photobucket.com/albums/l4...0.jpg~original

Lookin' good, can you lower those tanks down some to lower your CG?

Jason

That's about as low as I can get it and still have room for the battery. There's a couple of hoses and the oil temp sensor that stick out of the bottom of the tank that limit how low it can mount. It's about the same height as my torso so I don't imagine it'll hurt CG too badly. It's also only going to be 1/2 to 2/3rds full so the oil will sit low.

The water tank is a different story. I need it up higher for accessibility reasons (refilling easily and quickly) and it's only a 1 gal tank. If I get a larger tank in the future I may mount it up front instead.

Oh yeah, I forgot about the battery, I was thinking you'd moved it up front to play with weight distribution. I doubt it's matter too much anyway, you'll be powersliding through the corners!!!

Jason

Ah but that does matter for power sliding!:) The battery in the standard position is on the axis of the C of G and therefore contributes very little to the polar moment of interia. Stick it out front in the spare wheel well and it adds a significant amount to the Inertia that will actually make the vehicle less responsive.

evilC

Update time!

I really wish I could spend more time working on the race car. Actually, now that i'm (finally) divorced and working a little less that dream may come true just in time for the rainy season. Rain and time seem to be my worst enemies.

Got some time in friday and today (before it rained me out) working on wiring, vacuum lines and the oil cooler. I made a frame for the oil cooler out of 1.5" aluminum angle and bolted it in place of some missing sheet metal. There's a bottom brace bolted to the oil sump to keep it from swinging around. It'll be a pain when it come time to adjust the valves but I didn't have any other mounting options for such a large cooler. I grabbed to race wheels for a test fit to make sure everything cleared and I think the oil filters are closer to the rim the the oil cooler. Both have plenty of clearance but I can't waith to get some slicks on those rims!

http://i93.photobucket.com/albums/l4...2.jpg~original

http://i93.photobucket.com/albums/l4...3.jpg~original

http://i93.photobucket.com/albums/l4...4.jpg~original

http://i93.photobucket.com/albums/l4...5.jpg~original

http://i93.photobucket.com/albums/l4...6.jpg~original

http://i93.photobucket.com/albums/l4...7.jpg~original

Looks very impressive!

Unusual but nice wheels. What make/width/ET are they? What do they weigh each?

Wicked, I still haven't made it out to the meets with you guys, right now my car is in fremont at work, the dizzy took a **** on me again, gonna get it warrantied AGAIN, and will shortly be going without one! Can't wait...

Wally:
The wheels are BSA 215a 18x8 et 50 in front and 18x10 et 45 in the rear. I don't know the weight off hand butt I'll toss them on the scales when I get home. Not the lightest wheels but it's hard to beat the price, $600! I'm going to paint the centers flat black and possibly paint the machined lip saturn yellow to match the car.

kuleinc:
Are you going to be out at the NAG meet this friday? I was going to try and make it this time around if the weather holds up.

Update!

Oil system is done, fuel system is done! Only wiring and some vacuum lines left.

First the oil system:

First thing was the output fitting on the dry sump which was a royal pain to tighten. I'm pretty sure that section of oil line will need a heat wrap on it.
http://i93.photobucket.com/albums/l4...4.jpg~original

That goes to the filters in the passenger rear fender, and since everything is ready the filters are in place now.
http://i93.photobucket.com/albums/l4...5.jpg~original

After the filters is the oil cooler in the drivers rear fender and the inline thermo switch right above.
http://i93.photobucket.com/albums/l4...8.jpg~original

Then line goes back underneath to the top bulkhead fitting leading to the input on the oil tank. The bottom bulkhead fitting is the output from the tank to the oil feed for the pressure side of the dry sump pump. The -12 line that just passes through a hole without a bulkhead fitting is the oil drain for the tank. I couldn't get any fittings to line up correctly using a -12 bulkhead in place (not enough hose for wiggle room).

http://i93.photobucket.com/albums/l4...6.jpg~original

http://i93.photobucket.com/albums/l4...8.jpg~original

On to the fuel system...

Finished up the last line which is the high pressure line to the back and zip tied up both feed and return lines. It's hard to read in the small picture but on the original you can see the sizes on the 930 MC which is 20mm for the front and 29mm for the rear. Perfect for the 4-pot turbo 944 brembos which are shared with the 930.

http://i93.photobucket.com/albums/l4...9.jpg~original

http://i93.photobucket.com/albums/l4...0.jpg~original

Got the front plumbing finished and the filter in place, I'll probably secure it with a clamp to keep it from rattling too much. I managed to get the tank straps done as well, quick and easy.

http://i93.photobucket.com/albums/l4...2.jpg~original

http://i93.photobucket.com/albums/l4...1.jpg~original

Since daylight was running out I didn't a bit of quick wiring. Bolted the ground lines for the fuel injection and ignition to the block. Also relocated the water injection controller to a more easily reachable location once the seat is in place.

http://i93.photobucket.com/albums/l4...3.jpg~original

http://i93.photobucket.com/albums/l4...9.jpg~original


It was really nice to make some tangible progress today. After wearing my hands down to useless lumps putting together a dozens hose ends and not seeing much visible progress was hard. Those hose ends are fairly easy to do but they are a huge time-sink when you have a lot to go through.

Of course the best reward came tonight after the sun went down. Me and me roommates went to see Trans-Siberian Orchestra in San Jose. I'm just floored, best damn show I've seen in a very long time.

Very nice progress! Love the braided 'everything' lines.

Amazing job so far!!!

Too bad you left unfinished the suby project it was a nice project also!!!

Keep us posted..

It was nice talking to you at the meet, my new dizzy is retarding itself. So it may be a while before I can make it out to the BLTN meet... Had to take the minivan to work today haha...

Just putting this where it belongs, it's good to be back on the GL forums!

Firstly I finally have all of my safety gear, the last piece was the def-n-der head and neck restraint which I really like but its not made for big shoulders (i'm 22" across the shoulders and 46" around the chest). I 'm worried that it's going to dig into my shoulders once I'm belted into the seat.

http://i93.photobucket.com/albums/l4...f/HPIM0273.jpg

http://i93.photobucket.com/albums/l4...f/HPIM0274.jpg

Now for the good stuff! I got my race tires as well and stuck them on the car yesterday. They are Yokohama A048 R, 235/40 18 front and 285/30 18 rear on 8' and 10" rims respectively. They look perfect on the car and really give the rear that "I'm hiding something big" stance. For grins I tried a rear 285 on the front and it's a perfect fit. I can also turn lock to lock without rubbing. How many bugs do you see that can tuck a 285 without rubbing, on the front?! I can go bigger on the rear if I move the oil filters and I could go as big as a 315 without moving the oil cooler. Even if I put the rear tires on the front, the rear is still wider than the front by a couple of inches. The front wheels are still using a 1" spacer but the rear wheels bolt directly to the hubs.

For reference, that's the old rear tire a 225/50 16 on the right.
http://i93.photobucket.com/albums/l4...y/HPIM0282.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0283.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0294.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0295.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0296.jpg

and more...

And the 285 on the front, oh it's mean!

http://i93.photobucket.com/albums/l4...y/HPIM0288.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0287.jpg

http://i93.photobucket.com/albums/l4...y/HPIM0286.jpg

Full lock and I still have an inch or so to play with.
http://i93.photobucket.com/albums/l4...y/HPIM0290.jpg

On the wiring front I have 5 more wires to run and then I'm done wiring. I have to replace the starter before I can start it because the kick solenoid isn't working, buit I expect to have it running this weekend.

http://i93.photobucket.com/albums/l4...y/HPIM0284.jpg

Damn, those tires are huge. :eek:

No pics this time but another update for this weekend. I finally finished up the wiring and went to turn the engine over and the starter didn't engage, it just spun. Checked the part number and it's the wrong part so I'll have to go exchange it this week.

FYI: you need an SR87 '76 and up bus starter if you want to use the stock 091 tranny on a type 1 motor. If you change the bell housing for a 002 unit and shorten the input shaft 1/2" or so you can use a type 1 starter.

Since I couldn't check oil pressure I moved on to the fuel system, setting up the fuel gauge (adjusting the empty point on the sender), and checking for leaks. Boy was there leaks. About a half dozen loose fittings in all the hardest to reach areas took the whole afternoon to fix but it's tight as a drum now. I was setting the fuel pressure regulator and I know the system can hold 70+ PSI without leaks. I set it for 50 PSI for now since it has to be 45 PSI at idle.

I also tested the porsche abs wheel speed sensor with the electric speedo finally and it worked like a champ. I tested the voltage output before but this was the first test with the gauge so I'm very pleased it works.

After the fuel system sprinkler issue I'm going to go through all of the oil fittings before the first oil pressure check to be safe. Then it's time to start the beast and break in the cam!

There is definitely an awesome 'look' that tyres like those give to a car, I like!

Those tires are WICKED! Do you have any more info on the speed sensor? I hate my cable and my speedo is on its way out...

Man that's impressive! How in the world did you manage doing that? Are those stock fenders? Did you use any spacers? What's the ET on those rims?
I just finished mounting the new suspension for the first time, and I could only use a 185/65/15 tire on the ET55 phone dials. I tried a 195/65 tire and it rubs on the fender. I'm only doing trial fits right now but I'd really like to know more of your setup.

the front fenders are 4" wider than stock and the rear are 5" wider than stock, that's how the tires fit :D The rims are 8x18 et 50 on the front and 10x18 et 40 for the rear.

The best fit I got under stock fenders was 205/40 17 on 7x17 et 55 turbo twists on my street bug. Fits perfect all the way around with 11mm spacers.

The sensor is for the abs pickup in the front spindle of a 968. I don't know if 944 turbos came with abs or not but there should be a boss for the sensor at a minimum. I'll try and get some pics tomorrow since I have to tighten mine now that I think about.

Oh.. and she runs, sounds mean as hell, and leaks a little oil here and there (gotta track those down tomorrow) video and more details forthcoming!

Bring on the video! :woohoo:

First videos!

http://www.youtube.com/watch?v=UMgz4PE00xs

http://www.youtube.com/watch?v=40JZL9VJ45Q


Cam break in is done just need to get the axles back in, throttle cable in and clutch cable in to drive her. Still chasing leaks :angry: both valve cover gaskets wont stop leaking and a small drip (now) coming from underneath. I'm worried it's the cam plug or rear main. It was gushing oil before after some fuel got in it, so I changed the oil and the leak lessened by a good margin but it still there. Other than the oil leak and systems are doing well. All the gauges work and and wiring is looking nicer.

2 suprizes though: First the turbo doesn't quiet down the motor as much as I thought it would and noise may be an issue as some tracks. Second, I can't hear the CB straight cut cam gears at all, not even a little bit (exhaust is probably too loud.

Pictures!

Here's the wheel speed sensor, from a 928 not 968 (my bad).

http://i93.photobucket.com/albums/l4...1.jpg~original

http://i93.photobucket.com/albums/l4...5.jpg~original

And nicer wiring shots and fire extinguisher mount

http://i93.photobucket.com/albums/l4...7.jpg~original

http://i93.photobucket.com/albums/l4...8.jpg~original

http://i93.photobucket.com/albums/l4...9.jpg~original

http://i93.photobucket.com/albums/l4...0.jpg~original

http://i93.photobucket.com/albums/l4...1.jpg~original

sounds real nice :D
and what we didn't get to See the Drive way on Fire lol :lmao:
can't wait to See it all done...

Chris.

Great to see it breathing. Thanks for the videos. Can't wait to see some in-car from the track.

Yeah, I didn't have the camera out for the driveway fire but here's what happened. I slipped another race muffler I had over the turbo to take the edge of during cam break in. It exited even with the driveway and my roommate grabbed a piece of wood to hold the muffler in place. Well the wood went up pretty quick and where the exhaust was hitting the driveway also burned.

The bad news: I'm pretty sure it's the rear main leaking after talking to a few people. So now the motor will have to come out again. :bawling: I'm going to try and work fast to get it back together because that start up video is a pretty big carrot. I figure a week or 2 for tear down and reassembly before it's ready to go back into the car.

The good news: I've been progressively more and more unhappy with the 091 tranny. Working around it, staring at it, and having to modify a bunch of things to get it to work, and I keep hittng myself with the KISS rule, keep it simple stupid. Since the motor has to come out anyway I threw money at the problem (which I should have done at the start) and ordered a real race tranny from Rancho. It's a built to the hilt type 1, albins gears, ebw hubs, steel forks, type 2 flanges, and the list goes on. I'll recoup some money selling the 091 and other unused parts. The tranny should be here about the time the motor is ready to go back in and I already have a full tranny strap kit with urethane mounts from the old setup.

More progress on the car, 2 steps forward 1 step back. Not only was the rear main leaking but the sump tank emptied itself into the crankcase over the week. It made a real big mess on the driveway as it came pouring out of the bad valve cover gaskets. Ran the motor briefly to empty it, then drained the tank so I could move it. Before I could drop the tank though I had to move the battery. The battery ended up in the forward part of the passenger footwell and I installed the battery cutoff switch while I was at it.

http://i93.photobucket.com/albums/l4...3.jpg~original

http://i93.photobucket.com/albums/l4...4.jpg~original

With the battery out of the way I could lower the sump tank about 6" or so. The old bottom mount became the new top mount easy enough but I had to redo the -12 drain line. The old drin line was 4 feet long while the new one is about 4 inches long. It come right out of the tank and right into a bulkhead -12 union with a plug on the backside. It exits in the inside rear corner of the pan down at an angle which should be easy to reach for oil changes. I also lowered the water injection tank for good measure and put it right behind the passenger seat.

http://i93.photobucket.com/albums/l4...2.jpg~original

After I wrapped up the inside again I replaced the valve cover gaskets and fired her up again to check for leaks. So far the valve covers are dry and so is the interior. If all holds well then she comes back apart for the rear main seal and tranny swap.