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  #46  
Old February 24th 2010, 14:36
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Dimensions for what bits? It's a 3/4" ID spherical bearing with matching housing (from ebay) that was welded in to the 6mm thick plate. The kerscher struts have a 14mm thread, so the bearing needed sleeving down with some 3/4" thick-walled tube drilled through and an angular spacer welded on to the bottom to give a decent area for the top spring hat to sit on...

100mm sounds right for speedbumps (not questioning you there!), good to know about the kerb height though as I do normally hold my breath when going close!
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  #47  
Old February 28th 2010, 17:18
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Idle air control valve return pipe uses cut down standard pipe.


Header tank is from a Vauxhall Corsa/Tigra as it had the right connections. I didn't like the subaru system as it is based on an external overflow tank. An aftermarket one would have been solid aluminium so levels are not so easy to check. I welded on a couple of brackets to the body to support the standard fitting points on the tank


Fill point is accessable when the decklid is open.


The OBP pedal box had no provision for the throttle cable so this is what I came up with. I also made up the cable from a universal kit using the subaru fittings/adjuster on the engine end. It feeds through the standard tube in the chassis tunnel.


VW polo heater matrix/blower fan will be mounted to access panel and will blow in to the existing ducting behind the dash. I will fabricate an intake for the fan so it draws in air from the scuttle grill.
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  #48  
Old February 28th 2010, 22:35
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Are you happy with that return spring?
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1962 SC 1776cc SP 944NA brakes, 993 wheels

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  #49  
Old March 1st 2010, 11:40
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In what way? Don't forget there is a good return spring at the throttle body too and I need to keep space for the brake bias adjuster mechanism above it...
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  #50  
Old March 1st 2010, 22:01
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From the pic it just looks like the spring is at an angle that will cause accelerated wear at the mounting points. But, if you have a good return spring at the throttle body than it wont really matter anyway
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1962 SC 1776cc SP 944NA brakes, 993 wheels

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  #51  
Old March 20th 2010, 17:49
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I thought the body line above the trim didn't look quite right and this is what I found under all the filler! NOS VW 1/4 panels are no longer available so I went down to my local VW breakers, angle grinder in hand!


This is what was left after cutting out all the bodged repairs of the past


Donor section clamped roughly in place, it took a bit of searching to find one this good as it is a common rust area, unfortunately it was balanced on top of another car and was full of suspension parts!
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  #52  
Old March 20th 2010, 18:15
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Very nicely done resto job on that quarter panel Rich!
That must have costed a lot of time and effort to get to this end result. Points for motivation 4 sure!
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  #53  
Old March 20th 2010, 19:08
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It's only roughly clamped in place, not even trimmed to fit yet! I have to do some local internal flange repairs first too...
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  #54  
Old March 21st 2010, 05:08
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Could (did) have fooled me

Will you do any further tuning to the engine once everything else is done?
You know, bigger turbo and all that
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  #55  
Old April 5th 2010, 05:59
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Fantastic build!! Very professional! I really like your solution with the air filter and decklid behind the back seat! Really awesome!
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  #56  
Old April 5th 2010, 15:22
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Had a good couple of days on the rear 1/4 panel...
All hidden areas were treated with Bilt Hamber Hydrate 80, then painted, weld areas were taken back to fresh metal and Roberlo weld through copper primer used.


Tacked in...


Fully welded...


all welds ground down


couple of coats of Hydrate 80 to protect the fresh metal before I get to paint, it will only need a very small amount of filler at the weld seams..




Wally: the plan is to get it all de-bugged with this engine, should be an easy 300bhp with ported bits and pieces and the td05. Then later on up the capacity to a 2.5, either using a 2.5 sti bottom end or maybe getting this closed deck block sleeved to 2.5 for a really strong block, then comes bigger turbo etc etc and maybe 500bhp? Got to make that trans work for its living, lol!
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  #57  
Old April 5th 2010, 15:58
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Quote:
Originally Posted by ricola View Post
Wally: the plan is to get it all de-bugged with this engine, should be an easy 300bhp with ported bits and pieces and the td05. Then later on up the capacity to a 2.5, either using a 2.5 sti bottom end or maybe getting this closed deck block sleeved to 2.5 for a really strong block, then comes bigger turbo etc etc and maybe 500bhp? Got to make that trans work for its living, lol!
Thats good to hear! and when the real fun begins. Your basis is strong enough for those sort of plans
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  #58  
Old April 5th 2010, 17:56
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Or the other option is an EZ30, (newer model 3l flat 6 subaru) that with a turbo can release a LOT of power, Perrin performance have a very good developmental story, it's only 0.7" longer than the flat 4 so would still fit under the bug's body, worst case I could always shorten the bellhousing!
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  #59  
Old April 16th 2010, 15:19
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Bit more done today, sorted the exhaust tip and modified the rear valance to match. Left cutout was filled with section from old panel. I got the panelbeating hammers out and widened the right cutout to match the 3" exhaust..
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  #60  
Old April 16th 2010, 17:32
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Reminds me of the GT3 RS and Boxter S, I love those dual tailpipes!





Jason
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