Landracing Forum
Bonneville Salt Flats Discussion => Build Diaries => Topic started by: aircooledtechguy on April 30, 2014, 12:16:57 PM
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This car has been a long term project of mine that has gotten WAY out of hand and has taken a turn for the
worst better.
I've built it in phases along the years, and I've waffled on mainly styling aspects, but in the past year it just took a turn for a more serious racer. It started out as a humble '67 VW Squareback that I originally bought for my wife. A brief overview is that it is a modified '67 VW Squareback that is currently running a 2056cc Porsche 914 street motor. It will be upgraded to a 2.3L in the coming weeks by my son Josh who will be building the new race motor. It's going to be getting an upgrade in the EFI from the current plenum based MS2 w/ EDIS to an ITB based MS3X w/ LS1 COP and full sequential injection. The trans is a Porsche 912E 5-speed, the front suspension/brakes are Porsche 911 and the rear suspension/brakes are Porsche 944. The whole progression thus far can be seen here: http://www.thesamba.com/vw/forum/viewtopic.php?t=495312
(http://images.thesamba.com/vw/gallery/pix/1191016.jpg)
While it's been built for road handling and track-days, we're going to be testing it at the WOS event this September and try our best to gain entry into the 130 club (fingers crossed). My son and I are hoping to have a really fun father/son trip out to the salt, see some really cool/fast cars and make some memories that will last a lifetime.
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Sounds like a great project. The salt can be addictive so get ready for 25 years of a high sodium diet.
Keep us posted on your progress.
BR
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My Ghia started out as a street car built for road handling and track-days also. It has turned into a full race car now. Good to see another VW build. Maybe i'll see you at WOS.
Mark
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My Ghia started out as a street car built for road handling and track-days also. It has turned into a full race car now. Good to see another VW build. Maybe i'll see you at WOS.
Mark
We'll be there for sure!! Every time I turn around, it's becoming a more and more serious racer and less and less a streetable car. .. I fully intend to keep blinkers tail lights and collector plates, but I'm finding it really easy to say, to hell with streetability; all-out performance is what I want. I'm finding that once you fall down the rabbit hole of all out performance, you never come back from it. :-D
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My Ghia started out as a street car built for road handling and track-days also. It has turned into a full race car now. Good to see another VW build. Maybe i'll see you at WOS.
Mark
We'll be there for sure!! Every time I turn around, it's becoming a more and more serious racer and less and less a streetable car. .. I fully intend to keep blinkers tail lights and collector plates, but I'm finding it really easy to say, to hell with streetability; all-out performance is what I want. I'm finding that once you fall down the rabbit hole of all out performance, you never come back from it. :-D
LOL...I'm already down that rabbit hole with my HHR... :-)
The Squarsche looks great! Really like those old VWs...
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I temporarily turned my attention to the bumpers this weekend. I’ve got a pair of fiberglass bumpers from Glass-Action in AZ (http://vwinnovations.com) and I’m to the point of needing them to be mounted in order to do trimming and such for the fenders. I also needed to graft on the air dam I purchased a while back too.
I began by cutting some 2” muffler tubing in half on about 10” lengths. Then I made some flat brackets with captive nuts with which to mount the brackets to. This way I could fiberglass the metal mount brackets to the fiberglass bumpers w/o requiring any thru-bolts to show.
I tossed the stock bumpers and brackets to the side and chose a thin, light set of early beetle bumper brackets. The front brackets were used on the rear of the Square and only required elongating the mounting holes slightly to fit like a glove.
(http://images.thesamba.com/vw/gallery/pix/1202866.jpg)
The rear beetle brackets were used in the front of the Square and required custom holes to be cut in the proper place and the excess cut off the back.
I prepped the bumper bottom and the air dam top with a 3” disc to remove the gel coat. Then I cut a slice in the center of the air dam to allow it to be splayed out a bit more on each end to fit the fiberglass bumper better. I temporarily put them together with some spring clamps to ensure they would work correctly together.
(http://images.thesamba.com/vw/gallery/pix/1202865.jpg)
I test hung the bumper/air dam combo onto the brackets and it fit well. With my car at the current height, the bottom of the air dam is currently 5” off the floor.
(http://images.thesamba.com/vw/gallery/pix/1202864.jpg)
(http://images.thesamba.com/vw/gallery/pix/1202863.jpg)
This air dam also has a rubber skirt that hangs down an additional 3”. So as it is, the bottom of the air dam will reside about 2” above the floor. Since I have infinitely adjustable suspension via the 911 front and adjustable spring plates rear, I will be able to get it to about 1” for racing purposes pretty easily. Woohoo!!
Now I’m off to consult with my friend, Jim who does fiberglass/carbon fiber for a living, to see how he recommends permanently bonding the brackets and the air dam to the fiberglass bumpers. . . More to come. . .
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The bumper and air dam combo look great!
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Look what showed-up today on the brown truck. . .
(http://images.thesamba.com/vw/gallery/pix/1203619.jpg)
I contacted my machinist and asked him to make it light, but not a bomb. . . He was able to remove 6.8# off of it right where it counts. Started out a portly 16.8#. Now she's a trim 10.0#!! Hell, my daughters have more crap hanging from their key chains than this thing weighs!! :-D
Should make for a lively rev'r and allow a lot more of the power to actually get to the tires!! This was the last piece I was waiting for before I could send the rotating parts to the balancing shop to get it all balanced to within .1 gram.
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My buddy hooked this brother up and used Plexis to permanently bond the bumper and air dam together. Then he fared the two together for a smooth seamless look. Now it's ready for a scuff, prime and paint. I added the flexible rubber bottom skirt to see how it looks together with the bumper.
(http://images.thesamba.com/vw/gallery/pix/1203971.jpg)
(http://images.thesamba.com/vw/gallery/pix/1203970.jpg)
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Plexus is a good one and those parts should stay together very nicely.
It all looks great. :cheers:
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Lots of mundane stuff this Saturday.
Fixed and pulled the drivers front fender into place to give it room for the front tires/wheels. Here's a couple before (stock) and pulled so you can see how much can be done with just your hands.
tire clearance begins with under 1/4"; ends with just over 1":
(http://images.thesamba.com/vw/gallery/pix/1206688.jpg)
(http://images.thesamba.com/vw/gallery/pix/1206686.jpg)
Subtle pulling can just be seen:
(http://images.thesamba.com/vw/gallery/pix/1206689.jpg)
(http://images.thesamba.com/vw/gallery/pix/1206687.jpg)
It should be noted that by pulling the fenders even by hand like this causes the door gap at the front of the door to get HUGE and filling/re-gapping is required after.
Added the driver mirror mount and filled the OEM mirror holes. Also filled the stock windshield squirter hole. In time, I'll be adding a set of OEM Porsche 911 squirters to the front hood.
(http://images.thesamba.com/vw/gallery/pix/1206685.jpg)
(http://images.thesamba.com/vw/gallery/pix/1206684.jpg)
Finally got a chance to mate-up the front bumper with the fenders in place to get a good look. For street driving, I probably won't run the rubber skirt. For the track though, it'll definitely be on there.
(http://images.thesamba.com/vw/gallery/pix/1206682.jpg)
(http://images.thesamba.com/vw/gallery/pix/1206683.jpg)
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As body work continues at my buddies house, I've turned my attention to the new motor. After 3 years of acquiring parts, I finally have the final pieces in hand and none too soon. The final pieces were the custom Web cam, and a custom set of Deves rings. So I mocked-up the bottom-end so I could clearance the H-beam rod caps so they wouldn't hit the cam lobes on pistons #2 & #4. I also had to modify and clearance a type1 pump and the cam bolts so they would all live in harmony as well as port the oil passage on the pressure side of the pump.
(http://images.thesamba.com/vw/gallery/pix/1212860.jpg)
I also took this occasion to get my deck height and calculate static CR for this motor. It's a dual purpose mill that will see street driving as well as track duties. I know that it's a compromise on both parts, but it's built more for the track since I always have my trusty 2056cc to fall back on if it's just not practical for street use. I was already having fun with the local H*nda V-tec dorks with the mild 2056cc, so this 2.3L stroker with an extra 75-80 HP should send all but the turbo'd guys home with their tails between their legs. :evil:
(http://images.thesamba.com/vw/gallery/pix/1212861.jpg)
Once I get the parts back from the balancer, my son Josh is going to build this motor as I look-on. I want him to get the credit/accolades for any wins the car gets in future events. He's stoked about the opportunity to *finally* build a motor after 5+ years of tear-down duty here at the shop. He's been the tear-down-king since he was 8 y/o and it's about time he did the deed. As I always say, families who build motors together, stay together. :-D
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Those are difficult motors to build and they scare me.
People think they're simple but man if you don't know your stuff........ :oops:.
I tried once back in the day when I raced Formula Vee. Only did two races and moved on.
The motor I built was a doggie of note and ran really bad.
There's an art to building those and I have big respect for you guys that can. :cheers: :cheers: :cheers:
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Those are difficult motors to build and they scare me.
People think they're simple but man if you don't know your stuff........ :oops:.
I tried once back in the day when I raced Formula Vee. Only did two races and moved on.
The motor I built was a doggie of note and ran really bad.
There's an art to building those and I have big respect for you guys that can. :cheers: :cheers: :cheers:
It's funny you should say that. I hear all the time from folks that come into the shop "how easy these are to build and work on". The air-cooled VWs have that reputation, but I have never found it to be true. I don't feel they are easier or more difficult than most motors of the era. What I have found is that they are fairly forgiving engines (at least in stock form) and as such will allow a complete fool to get away with some really foolish mistakes before they get bit in the @$$. :lol:
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You're good at what you do. Don't sell yourself cheap. :wink:
That little motor kicked our butt 40 ways from Sunday.
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My buddy who's doing the body work came by and grabbed both doors and the front left fender to work on and brought back the right rear fender. . . Man, this thing is coming together. Pics later on that; I have bigger fish to fry.
I concentrated on getting the engine parts 100% ready for the balancer and the rear valance.
On the motor side, I only needed to notch the H-beam rods so that a stream of oil would spray on the bottom of the piston crowns. This cools the pistons and cooling can't be a bad thing right?? Bel0w is the un-modified rod:
(http://images.thesamba.com/vw/gallery/pix/1214002.jpg)
Below is the modified rod.
(http://images.thesamba.com/vw/gallery/pix/1214001.jpg)
I used a three sided hand file to make the groove in just a few strokes. This channels the oil splash off the rod the and forces it to the back side of the piston in order to cool the crown. This 5 minute mod, can cool the pistons by 30F+. Well worth the time.
Now I turned my attention to the rear of the car. A month or more, I removed the factory rear apron; it was bent and generally wasted. I wanted to remove it and replace it with a panel that would breath and allow the natural vacuum of the car to draw not only the engine cooling air out, but also the air under the car. I decided to make a rear diffuser of sorts. I started by tracing out the rear profile onto a template material. Then bolted-up the fiber glass rear bumper, to ensure it would exit just under the bumper.
(http://images.thesamba.com/vw/gallery/pix/1214015.jpg)
(http://images.thesamba.com/vw/gallery/pix/1214013.jpg)
(http://images.thesamba.com/vw/gallery/pix/1214012.jpg)
(http://images.thesamba.com/vw/gallery/pix/1214011.jpg)
Then I welded it in place.
(http://images.thesamba.com/vw/gallery/pix/1214009.jpg)
(http://images.thesamba.com/vw/gallery/pix/1214007.jpg)
The entire area under the rear will be mesh but I'm still waiting on that from the supplier.
On the front of the car, since I'm going to run small Braille 18# battery that will be totally contained between the spare tire and the nose skin of the front apron, jumping it will be impossible. So I added a pair of remote battery terminals for jumping the car if that was ever necessary. I picked these up on eBay cheap. This week, I'm going to be carefully measuring the cables needed and getting them made locally.
(http://images.thesamba.com/vw/gallery/pix/1214010.jpg)
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Out with the old. . .
(http://images.thesamba.com/vw/gallery/pix/1215156.jpg)
The 2056cc comes out to make room for the new 2.3L that will replace it. With a little luck, my son may begin the build-up this Saturday if I can get the parts back from the balancer by Friday. Only the cooling tins and alternator will move over to the new motor. All the injection and exhaust will be new, one-off pieces.
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So as body work continues (cough, hack, puke), I took a break from that work that I hate(!) and jumped back on a fab job that I began a couple months ago. I got to the point that I needed to install my mock-up motor so I could finalize the racing exhaust pipe location as well as finish making the custom air box for the ITBs. Believe it or not, this was my first test fit of the mock-up motor with the new mount bar, exhaust and ITBs in the car. . . LIKE A GLOVE!!!
I began by dragging out a pair of relatively hard to find Porsche 2.0L air cleaner assemblies. I made some cut lines and began cutting them both to pieces in order to come-up with basically a square center box with a short, but better breathing wide snout.
The vision. . .
(http://images.thesamba.com/vw/gallery/pix/1218844.jpg)
(http://images.thesamba.com/vw/gallery/pix/1218843.jpg)
After the cutting was done, the left over pieces went into the recycle bin. . .
(http://images.thesamba.com/vw/gallery/pix/1218842.jpg)
I welded the pieces together and ended up with a center air box that fit great.
(http://images.thesamba.com/vw/gallery/pix/1218841.jpg)
Then I ordered four 90 degree silicone boots and cut about ¾” off one end so they wouldn’t be too tall and fit under the factory type3 engine cover.
(http://images.thesamba.com/vw/gallery/pix/1218840.jpg)
Then I marked out where the 2” pipes would come into the center box and hole sawed the sides of the center box. I used some 2” muffler pipe to make the pipes leading out to each ITB silicone elbow and tacked them in place with the MIG.
(http://images.thesamba.com/vw/gallery/pix/1218839.jpg)
I’ll finish weld them tomorrow since it’s been a pretty long day thus far. Eventually it will get powder coated like the engine tins for that "factory skunk-works" look and a fresh K&N element.
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Nice finish.
It looks factory/race to me. :cheers: :cheers: :cheers:
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Finally, the fender stretching is done!! Got the drivers side rear finished-up yesterday evening and it feels good to have that all behind me. It came out pretty darned good but was a bit tedious to get the same as the left side.
(http://images.thesamba.com/vw/gallery/pix/1220196.jpg)
I also shaved the inner edge of the fiberglass bumpers in order to allow them to fit since the fenders wouldn't allow proper fitment without it. Luckily there's enough meet on them to trim around 1/2" off and still have them look un-modified.
(http://images.thesamba.com/vw/gallery/pix/1220198.jpg)
I still have a bit of under fender work to do, but the part everyone see's is done. I really like the "fat squatting" look from the rear with the fat tires and the 911 banana can poking out. I may reposition the exhaust tip a little higher, but all in all the look of the rear is about where I wanted it.
(http://images.thesamba.com/vw/gallery/pix/1220197.jpg)
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NICE WORK :-) :-) :-)
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Took about an hour to shorten these IDF/DRLA manifolds 1 3/4" so they would fit into the Squarsche. I cut them apart on a band saw.
(http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1403051493.1.jpg)
Then after beveling all the edges so I could get good penetration, I TIG welded them back together again. Then after they cooled down, I used a burr to smooth out the transition on the inside for good flow from the ITBs.
(http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1403051494.2.jpg)
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Nice job. :cheers:
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This Saturday, I got the sway bar mounts made (well mostly made) and test fitted.
(http://images.thesamba.com/vw/gallery/pix/1223734.jpg)
I also tweeked the entire throttle cable system and get it swapped over from the single TB location to the new location that works with the ITBs on this car. This also called for a custom cable, cable sheath extension and some other stuff so that it would work in this bastard step-child of a car. The result is a SUPER smooth cable linkage. The system is from Tangerine Racing and is a piece of art. If you want smooth linkage that is simple to sync and clean, this is the only set to get.
(http://images.thesamba.com/vw/gallery/pix/1223733.jpg)
Today, my son Josh began assembling the bottom-end of the new race motor. He's doing a great job so far and I'll post photos of that when the bottom-end comes together.
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Nate, that's a super cool sway bar system and the car is coming along great. :cheers:
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Beginning this week, my son Josh has been out of school and is coming in to give his old man a hand at the shop. But it’s not without a mission. Since he was about 8 y/o, he’s been coming in occasionally to help when he needed some extra money to buy stuff kids buy. Over the past 6 years or so, he’s been my tear-down/parts-washing king. The un-disputed king at that. Now that he is 14 y/o he’s earned a new job. . .
Monday and Wednesday, he spent the better part of both days assembling the 2.3L race motor that will be the new heart of the Squarsche. What follows are a few shots of him assembling the bottom end. I have to say that he has really listened well and is doing a bang-up job on this motor so far. I couldn’t be more proud. . .
(http://images.thesamba.com/vw/gallery/pix/1224868.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224867.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224866.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224865.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224864.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224863.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224862.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224861.jpg)
(http://images.thesamba.com/vw/gallery/pix/1224860.jpg)
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Nate, I envy you and your boy- especially him. it looks like he's having a fine time - and whether he knows it or not he's learning stuff that'll follow him for the rest of his life. Corngratulations to both of you. Keep up the good work. :cheers: :cheers:
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Thanks Jon. While we'll be aggressively trying to get into the 130 club and do everything in our power to make it in, privately my goal is to just have a great time on our trip down to the salt and hopefully make some memories with my son that will last a lifetime.
Josh is going to miss his first week of high school in order to make the event, but something tells me he'll learn a lot more at Bonneville than he would sitting in class. . . 8-)
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It's good to see a young guy doing what Josh is.
Not a common sight around where I live.
Way to go guys. :cheers:
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Thanks Jon. While we'll be aggressively trying to get into the 130 club and do everything in our power to make it in, privately my goal is to just have a great time on our trip down to the salt and hopefully make some memories with my son that will last a lifetime.
Josh is going to miss his first week of high school in order to make the event, but something tells me he'll learn a lot more at Bonneville than he would sitting in class. . . 8-)
That is great. And he is a good mechanic! Tell the teachers he is studying global warming in the salt desert and they will probably give him an "A". It is fun to see how fast it will go whatever it is and whatever the speed may be. Enjoy.
BR
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Tell the teachers he is studying global warming in the salt desert and they will probably give him an "A". It is fun to see how fast it will go whatever it is and whatever the speed may be. Enjoy.
BR
You got that right!! This trip will be a years worth of extra credit with the teachers I deal with here. :roll:
Got my fenders and doors back from my body guy, so I hung them on and dragged her outside so I could take a shot for the official program for the World Of Speed event in Bonneville. It's sitting a little @$$-high since there's no motor in it. All in all, the debauchery is coming together nicely. . . :twisted:
(http://images.thesamba.com/vw/gallery/pix/1230231.jpg)
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I had Josh trace out and cut the second inner fender well panel for the Squarsche today. He'll be doing a mirror image of what he watched me do yesterday on the passenger side.
(http://images.thesamba.com/vw/gallery/pix/1232222.jpg)
(http://images.thesamba.com/vw/gallery/pix/1232221.jpg)
On the passenger side I marked and welded in the dzus anchors I bought from Speed Mart into the OEM inner fender well. This will act as an air duct to bring cooling air from the NACA ducts fwd of the rear wheel, over the rear wheel and straight into the OEM cool air duct at the back of the car. This will help to force-feed the fan at speed. I went this route rather than just switch to the later fender grills and *hope* enough air would find its way into the fan.
Since we're running at Bonneville, we had better be able to clean the ducts out after racing, so they are being held in with dzus fasteners. Here's my side:
(http://images.thesamba.com/vw/gallery/pix/1232220.jpg)
(http://images.thesamba.com/vw/gallery/pix/1232219.jpg)
(http://images.thesamba.com/vw/gallery/pix/1232218.jpg)
His side to follow and I'm sure it'll be better than mine. . .
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So,. . .
My client and friend named Al Benda stops by the shop just a few minutes ago. . . Now Al is the guy that stopped by two years ago after WOS 2012 and brought me the event program that has in time, SCREWED me out of more time and money now that I’m bringing a car to this years WOS event for a run at the 130 Club. . . (Damn him!!)!!!!!!! Every time I see him here in town, I both wave and curse his name all at the same time. . .
Anyway, he stops by and brings me this shirt for motivational purposes (of course):
(http://images.thesamba.com/vw/gallery/pix/1234213.jpg)
Yeah, I have every intention of buying him a replacement shirt this year. . . Damn it, I LOVE THIS GUY!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
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At least you know the guy on a face to face basis!!! :-D
The guys that got me into the "addiction" are just nicknames and email addresses. :evil:
Good story though and more like watching a movie than reading.
That IS the shirt. :cheers: :cheers: :cheers: :cheers: :cheers: :cheers:
Best post in a long time. Thanks man.
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NICE BUILD
You're making me want to take mine damnit
(http://i586.photobucket.com/albums/ss306/Fiatdude/20140712_121133_zps1a0dfd00.jpg) (http://s586.photobucket.com/user/Fiatdude/media/20140712_121133_zps1a0dfd00.jpg.html)
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NICE BUILD
You're making me want to take mine damnit
(http://i586.photobucket.com/albums/ss306/Fiatdude/20140712_121133_zps1a0dfd00.jpg) (http://s586.photobucket.com/user/Fiatdude/media/20140712_121133_zps1a0dfd00.jpg.html)
No balls if you don't!! (Oh crap I just called your man-hood into question; now you have to bring it!!) :-P :cheers:
No pics today. . . Just verbage.
Had a couple days that disappointed me and ended up as wasted time, which I can't afford at this point with less than 50 days to go before World of Speed @ Bonneville. Anyway, progress was made on 2 fronts. . .
1. I got the inner fenders sealed for the NACA ducts to bring cooling air to the engine. This was huge. Originally, I had grandiose schemes of ducting from the NACA ducts to the inner fenders, however I had grossly over thought this. All I needed to do was to prevent air from traveling from the NACA ducts to the rear section of the fenders and attempted a fiberglass ducting system to make this happen. . . I lost a n entire day on this fiasco. A simple 6" wall prevents this and the "lazy air" will have no choice but to go down the duct over the rear tire and into the engine. Woohoo!! A HUGE burden has been lifted off my shoulders. . .
2. I now have brakes. Yeah, racing at Bonneville make brakes kind of the last thing you need to be concerned about, but it was forward progress, so I'm counting it today. I need all the fwd progress that I can get.
3. I found the perfect seals on Ebay for the inner fender/outer fender and I'll be ordering them tonight.
I may start throwing receipts away on this project. . . This sh*t is getting expensive and completely depressing . . I'm a freakin' privateer on a shoestring budget and and prayer!!!!!!!!!
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"I may start throwing receipts away on this project. . . This sh*t is getting expensive and completely depressing . . I'm a freakin' privateer on a shoestring budget and and prayer!!!!!!!!!" You're sounding like the average Bonneville competitor Nate. :-D :-D :-D :roll: :evil:
Pete
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Right on Pete.
There should be a standard "post" like that, that we can just copy and paste. :-D
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After weeks of delays due to shop and family commitments as well as part incompatibility issues, Josh was finally able to finish the engine build that he started several weeks ago. None too soon I might add since it is getting down to the wire on this project!!
One of the issues we had was when I ordered a ring set, TWICE, I was sent the wrong oil control rings. Each time, causing a week or more in delays. . . Man was it nice to get those cylinders on and the motor finished. Here are a few shots of Josh back at it getting the cylinders prepped and heads on and torqued.
(http://images.thesamba.com/vw/gallery/pix/1240614.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240613.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240611.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240612.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240610.jpg)
After we determined our rocker geometry and made adjustments via shims and push rod length, Josh got down to making the custom length chromoly push rods. He did a fantastic job!!
(http://images.thesamba.com/vw/gallery/pix/1240609.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240608.jpg)
He then was able to get the modified 1.7L rockers w/ OEM Porsche 911 adjusters installed and the valves adjusted.
(http://images.thesamba.com/vw/gallery/pix/1240607.jpg)
We’re going to start the motor with these bolt-on covers. Yeah, yeah, I know; they will probably leak, but we gotta try ‘em anyway since they’re easy to change out for stockers. . .
(http://images.thesamba.com/vw/gallery/pix/1240606.jpg)
Before the engine tins went on, we set the air gap at the hall sensor and 36-1 trigger wheel to 3mm and verified a good signal with a multimeter. We wanted to do this now since getting at it later will be “fun”.
Then began the job of the engine tins. We robbed these off the old 2056cc and cleaned them-up.
(http://images.thesamba.com/vw/gallery/pix/1240605.jpg)
After that, we mounted the ITBs and synced the linkage, which only took about 30 seconds (try syncing any other type of linkage that fast).
(http://images.thesamba.com/vw/gallery/pix/1240641.jpg)
Then I had Josh break out the torch and anneal the copper exhaust gaskets so they would be butter-soft for good stub sealing.
(http://images.thesamba.com/vw/gallery/pix/1240643.jpg)
After they cooled, he installed them into the ports, anti-seized the studs and mounted the custom stubs using OEM Porsche 914 2.0L exhaust nuts.
(http://images.thesamba.com/vw/gallery/pix/1240642.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240639.jpg)
Below is a shot of Josh and his first motor build. I’m really proud of him and what he has created here.
(http://images.thesamba.com/vw/gallery/pix/1240640.jpg)
Today, I had to make an exhaust hanger just before the V-band. With the 911 muffler, this is not needed, but if I run a straight pipe like at Bonneville, it will need to be supported. This is what I came up with.
(http://images.thesamba.com/vw/gallery/pix/1240637.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240638.jpg)
Then we got the header on and the muffler installed.
(http://images.thesamba.com/vw/gallery/pix/1240636.jpg)
(http://images.thesamba.com/vw/gallery/pix/1240635.jpg)
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Nate, you should be proud. :cheers: :cheers: :cheers:
Josh, you did a nice job there. :wink: :cheers:
I stick by my statement. Those are not easy motors to build.
You made it look easy. I hope you get every HP out of it you want.
Great build guys, thanks. Mike.
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I'm impressed. He did it with a look of enthusiasm and enjoyment the whole time and he didn't need headphones to accomplish the job.
Great work Josh!!! :cheers: :cheers: :cheers: (root beer, I'm sure! :-D )
Pete
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Thanks for the kind words guys. Even through all the smart-@$$ness, I think Josh is picking this stuff up pretty good and is doing a great job on his part.
I made some more progress yesterday. I modified the tank (via BAH :lol: ) and got it mounted. That enabled me to be able to finalize the front strut bar and weld-in the studs for it.
(http://images.thesamba.com/vw/gallery/pix/1241954.jpg)
This is the first front stiffener to go in. I'm going to be doing some testing in the months to come to see if more will be needed.
I also made the spoiler stiffener support and mounted it to the inside of the spoiler. This is necessary because all the force of the air at high speeds will eventually break the mounts for the bumper since they are just fiberglassed in place. This will support the bottom really nicely and make it solid at high speeds. I still need to make the strut bars that tie it to the front suspension, Since I ran out of materials.
(http://images.thesamba.com/vw/gallery/pix/1241955.jpg)
I also mounted & plumbed the Walbro fuel pump and filter as well as ran all the front fuel hoses.
(http://images.thesamba.com/vw/gallery/pix/1241953.jpg)
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I got the new motor stuffed in the car and some other details wrapped-up today as well.
(http://images.thesamba.com/vw/gallery/pix/1243306.jpg)
(http://images.thesamba.com/vw/gallery/pix/1243305.jpg)
(http://images.thesamba.com/vw/gallery/pix/1243365.jpg)
(http://images.thesamba.com/vw/gallery/pix/1243364.jpg)
So far the ride height as it is allows 3" at the flex-dam and 4" at the trans mount/skid plate and the sump. I'll be raising up an inch or so before any street driving just to be safe, but will lower it 1.5" front and another inch in the rear for Bonneville.
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Nate;
Your "Squarsche" is looking great. Which transaxle are you using? Stock gearing?
Regards, Neil Tucson, AZ
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Nate;
Your "Squarsche" is looking great. Which transaxle are you using? Stock gearing?
Regards, Neil Tucson, AZ
Thanks for the kind words Neil. We're running a Porsche 5-speed out of a '76 Porsche 912E. Gearing is stock. For LSR, I would prefer to run a 915 since the R&P is higher geared, but I would need to have a special clutch disc made in order to run it. Maybe next year. . .
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Thanks. I used a Porsche transaxle from a 914 in a Sable sports racer that I built. Nice little tranny-- the 901 is much lighter than a 915. You might give California Motorsports a call; they are the best (I'm told) Porsche transaxle guys and they do work for other shops. They might have taller gearsets for your 901.
Regards, Neil Tucson, AZ
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Actually the trans that I'm running is effectively a 915 trans. It was a one year only type of 915 that only came in the 912E. It's basically a 915 with similar gearing 1st-5th but with a 901 main shaft (so it uses a 901 215mm clutch disc) and has a different clutch actuation arm (for an early push style clutch). The other main difference is the R&P. It's got a lower R&P than a 915.
All these unique differences were so it could be run with the 2.0L type-4 motor out of a 914 that powered the 912E. It's got perfect gearing for the engine for driving around town, hwy and track use, but I think for LSR I would benefit from the longer legs of the taller R&P from a 915. The only thing that stops me from installing one is that there is no clutch disc available currently that has the larger 915 main shaft spline on a 215mm disc. . . I may have to make one. . . :evil:
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Try calling KEP.
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I got my bottom brace for the front spoiler finished today and I'm really happy with it. The spoiler is really solid now and the only flex is in the rubber base skirt (as it should be). This ties into the front suspension for strength.
(http://images.thesamba.com/vw/gallery/pix/1244995.jpg)
Over the past couple days, I turned a mess of a wiring system that was hanging half way to the floor into a working, correctly routed dash. My friend Robert helped me out by extending the gauge wiring a few weeks ago so it made it a lot simpler. Thanks Robert!! This thing is coming together!!
I also wired-in the new custom steering column. My original '67 column was fine and I could have modified it to work with the 911 steering, but it was a single stalk column and I really wanted to have the wipers up by my hands. Having to reach to the dash for it every 30 seconds with this PNW drizzle we get up here gets old on about 2 miles of driving. So if you remember, I severely cut down a '73 Super Beetle dual stalk column. Yesterday afternoon and today, I attacked the wiring and got them all wired-in. The 13 pin blinker went the way of the Dodo bird and I now have an electric flasher unit for the LED lights. As time allows, I may add an emergency flasher box by way of a couple diodes, but there's just no time for such things now.
(http://images.thesamba.com/vw/gallery/pix/1244993.jpg)
(http://images.thesamba.com/vw/gallery/pix/1244992.jpg)
I also got the driver's seat re-installed for the first time in a long time. That felt good too. I sat down in the drivers seat for the first time since about March of 2013 and it was like re-uniting an old friend that you have been missing. . . I can't wait to beat the crap out of this old friend!! :evil: 8-)
(http://images.thesamba.com/vw/gallery/pix/1244994.jpg)
I also got the coils mounted on the engine and a new set of plug wires routed and cut to length with the correct air-cooled ends. I found that a Bosch set of Vanagon (hack, cough, puke. . .) wires have the correct 90 degree fittings on the coil end for the LS style coils. Just cut them to length and the air-cooled plug ends/seals just screw on like factory.
(http://images.thesamba.com/vw/gallery/pix/1244991.jpg)
Friday is the big day that Mario Velotta from www.thedubshop.net comes over to my shop with the new MS3X ECU, custom wiring harness and cam sync so we can get this beast fired-up, broken-in and tuned.
Man I can't wait to drive this thing!! All in good time. . .
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Yesterday was a day of progress, steps back and delays. Isn't that just typical of racing??
On the progress side, my Thursday trip to the San Juans to fix a car got canceled so I was able to have Mario come out a day earlier. We hit it first thing in the morning and by noon, the engine wiring harness was made and installed on the engine side. By 4pm, the entire EFI system was live and all sensors, coils, injectors and triggers were tested and checked good. In that regard a lot was accomplished. We stopped just short of starting the motor. That's where the step back came into play. . .
The step back came around noon when it was time to install the cam sync on the distributor hole. I had not yet installed the distributor drive gear since having it in there without a dizzy to keep it in place will cause it to rise-up in the hole and bind if you hand crank the engine. Even though it doesn't really matter on this cam sensor how the drive gear is orientated, I still wanted to install the drive gear in the correct orientation. So I began to hand crank the motor with the only thing I can hand turn it with; the alternator pulley. As I got about 3/4 turn, the motor "clunked" and bound-up!! :shock: I turned it back the other way and the same thing. . .
So we began the deconstruction to eliminate possibilities each time checking if it would turn. We checked the valve springs for binding (again) - good, removed the rockers - good, checked the valves with a straight edge - good borescoped the cylinders through the plug holes - good, borescoped the intakes through the ITBs - good. :? Everything was fine. The last time the motor had been rotated was during the valve adjustment and it was perfect. . . confident that it was not caused by anything internal, out came the motor. :evil:
Pulling this motor is not as straight forward as most cars since literally everything is custom on it. To fit in, it must be pivoted at a unit at about a 30 degree down angle on the fwd trans mounts, then you can separate it. 'Course that means you must disconnect all the shift linkage or you will destroy it and possible the trans nose cone and shift shaft. So as soon as we get it ready to separate, I loosen the final nuts on the bottom and shift the motor back about 1/4" and try turning the engine; IT SPINS FREE!! So now we know the issue is in the bell housing.
We separate the engine completely and the witness marks reveal that during the balancing process, a small amount of weight was needed to bring the pressure plate into balance with the rest of the assembly, so a small piece of steel was welded to the PP. Unfortunately, it was interfering with the trans case where the throw-out shaft is. . . So I used a burr to take down the boss on the trans case a bit and the problem was solved. Man, I'll tell you what, I'm gonna give my balancer some good natured crap over that one!! :-D
As for the delay, we decided to hold-off with the starting and tuning until Monday. By the time Josh and I got the motor back in, Mario was finishing up with the wiring inside the car and we would have had enough time to do the initial break-in at least, but there were a couple details that I had overlooked and taking the weekend to get those sewn-up I think would be the wiser move. I also wanted to take advantage of one of the nice features on this new MS3X ECU. I need to install, and wire-in, a momentary button and an LED light to my gauge panel. This will enable me to datalog at the push of a button straight off the ECU to a SD card so no device like a computer or bluetooth phone will need to be in the car for this purpose. This is important since I can't legally have a laptop in the car during a race session.
So all-in-all a good day. Not as great as I would have hoped, but progress was made and by Monday we should be starting, tuning and driving this pig!! :-D
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I had a 901 in my Ghia and destroyed the main shaft --- had some big 4th and 5th gears for it still in the tool box you interested????
(http://i586.photobucket.com/albums/ss306/Fiatdude/20140822_162159_zpsfkrph2nx.jpg) (http://s586.photobucket.com/user/Fiatdude/media/20140822_162159_zpsfkrph2nx.jpg.html)
PM me if you want them
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I had a 901 in my Ghia and destroyed the main shaft --- had some big 4th and 5th gears for it still in the tool box you interested????
(http://i586.photobucket.com/albums/ss306/Fiatdude/20140822_162159_zpsfkrph2nx.jpg) (http://s586.photobucket.com/user/Fiatdude/media/20140822_162159_zpsfkrph2nx.jpg.html)
PM me if you want them
Thanks for the offer. However, I don't have a 901. My tranny is a 923 from a 912E which is basically a 915 with a few quirks for a 4 cylinder motor. Again, I appreciate the offer. :cheers:
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Fiatdude;
What ratios are those 4th & 5th gear sets?
Regards, Neil Tucson, AZ
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Spent the day getting all the little details ready for Monday morning with Mario (Part 2). Here’s a couple shots of the offending weld and where it was hitting and binding on the bell housing and the fix for it. . .
(http://images.thesamba.com/vw/gallery/pix/1247348.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247347.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247346.jpg)
Got the motor re-stuffed (I’m getting really good at it and it’s scaring me.) With 2 jacks and 30 minutes it’s out and about another 40 minutes to go back in.
Here’s what it’s like with all the harness installed and zip-tied down. Super clean. IMHO, Mario from www.thedubshop.net makes the best harnesses you can buy.
(http://images.thesamba.com/vw/gallery/pix/1247344.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247343.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247342.jpg)
Speaking of Mario and his products, here’s a shot of the mini cam sync installed that he designed and makes for our motors. This takes the place of this unit from CB Performance and scales it down to about a 1/5th scale. . . Freaking amazing little piece and it works great too.
(http://images.thesamba.com/vw/gallery/pix/1247345.jpg)
(http://www.cbperformance.com/v/vspfiles/photos/7074-2.jpg)
So as of now, I have 5 gallons of Premium gas in the tank. The fuel pressure is set @ 35psi on the peanut gauge. I cranked the motor to prime it with oil until the light went out. Now all I have to do its wait until Monday morning. I've got the GoPros charged-up and ready to capture that sh*t-eatin' grin on Josh's face when that motor roars to life for the first time. . . Come-on Monday!!
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No time for the real paint job before Bonneville and the rules say that your car must have a neat, presentable appearance.,. . . so a quick bomb-can-job will have to do for now so she's all one color. I found the perfect color of grey that I was looking for too. Grey with a little brown in it.
My philosophy is: Go fast enough and no one will be able to notice the flaws!! :lol:
(http://images.thesamba.com/vw/gallery/pix/1247598.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247596.jpg)
(http://images.thesamba.com/vw/gallery/pix/1247597.jpg)
So far I have the roof, rear hatch and the front-end painted. The rest will be shot later in the week. I've got a GTG next weekend that I really want to drive it to so I can break-in the motor before Bonneville.
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Nate;
That color is close to a VW color they called "anthracite". Good luck, run fast, run safe.
Regards, Neil Tucson, AZ
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Nate;
That color is close to a VW color they called "anthracite". Good luck, run fast, run safe.
Regards, Neil Tucson, AZ
The exact color is Ford machine & implement Grey. :-D Piss-can available at Ace Hardware.
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:-(
In other news,. . .
The new motor has fought Josh and I from day one. Today was the biggest PITA I have had in recent memory. From now on, this car will be referred to as "Murphey's Squarsche" cause this pig is going to drive me to drink,. . . MORE. :-D
We have fought poor parts from the word go. Today we discovered that the pump cover was defective and it literally poured oil as soon as the oil light went out. Then we found a head leak caused by a bad cylinder. I can tell you with 100% certainty that I will NEVER, NEVER, EVER use AA cylinders again. I don't give a crap how much a set of Mahles cost.
So at the end of the day, we were faced with a decision: Continue to screw with the new motor with a dwindling time schedule, roll the dice and possibly not have a motor and then have no time to ready the spare motor. OR get the tried and true spare motor in with the new injection and make make it to Bonneville and run the ever loving crap out of this car. . . Not a decision I wanted to make, but not having a car to run is just not an option at this point. We're going and we're bringing a car to compete with. I promised Josh that we're going and I won't welsh on that promise. So a decision has been made. For now, we're going to shelve the 2.3L for this season and methodically work the bugs out when we're not under the pressure of a hard timeline. When it's ready, it's ready. The 2056cc will go in with the new injection and we're gonna run the wheels off this car. Period!!
We'll get these issues ironed out in time and it'll make the victory all the sweeter. For now I think it better to relieve the pressure a bit so we don't take un-due risk with 3 year$ worth of part$ acqui$ition and turn them into a pile of junk on the floor of the shop because we were pushing for a deadline. That's just foolish IMHO.
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Looking at the pics of your engine it appears that your injector inlet tubes are not "belled". The non belled design as you appear to have is giving up about 15% on inlet flow. I have an article by Dr. Gordon Blair that discusses proper inlet design it is to big to post on this sight so E mail me at rexschimmer@gmail.com and I will send it to you. Might prove interesting.
Rex
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Thanks Rex. I'll shoot you an e-mail today.
The Squarsche is ready for Bonneville!! The only thing left to do is to add a tow hook front and rear and get a 4-wheel alignment. Everything is painted and on the car now. I came out exactly as I had envisioned it. I've driven it about 400 miles in the past 3 days and other than the alignment (the rear is out badly), it really drives nice
As of Friday night @ 6pm. . .
(http://images.thesamba.com/vw/gallery/pix/1249847.jpg)
(http://images.thesamba.com/vw/gallery/pix/1249846.jpg)
(http://images.thesamba.com/vw/gallery/pix/1249845.jpg)
(http://images.thesamba.com/vw/gallery/pix/1249844.jpg)
(http://images.thesamba.com/vw/gallery/pix/1249843.jpg)
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Fantastic project -- Have a great time and look up the Black Line VW guys -- and Burly -- they are a hoot
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Nate, I think you already broke a record.
You finished that build in short time and it looks great.
Good luck to you and Josh. :cheers:
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Josh and I have the truck loaded w/ the car on the dolly and we're out of here before dawn headed for Bonneville.
Keep your fingers crossed. . .
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Nate and Josh,
Enjoyed seeing your car on the salt at WoS.
Sorry, but I just never made it to your pit to talk with you guys.
I did get this pic of your car in staging:
(https://lh4.googleusercontent.com/-RIJdTW_Jf34/VAvMk1uUB-I/AAAAAAAABsY/hXJX2lSyOn0/w800-h600-no/IMG_0055.JPG)
Gregg
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Nate and Josh,
Great to chat with you in the staging area. I have a couple of videos of your runs, but can not upload the to the forum. PM me and I can email them to you.
Scott
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How'd the little squarsche do?
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Air Cooled:
You are killing us... how did the air cooled do?
How was your first time on the salt?
Also, search the forum, there are pages and pages on how to get the salt out of your car after Bonneville.
BR
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Josh and I had a GREAT time at WOS!!! Met more folks than I can count and had a week of talking cars, checking out outrageously fast cars and driving as fast as I could in my own. . . Is there anything better??
The Squarsche was a little slower than we had hoped, but it wasn't totally un-expected with the plan-B motor installed. We were hoping to break 100mph in the standing mile. We ran very consistent with the 5 competition runs only varying by about 2.5mph. Our best run netted us 96.9 mph. Probably the best part of the way the car ran was the reliability; we never turned a wrench on her all week. We loaned tools but never used them ourselves. We just hopped back in line and waited our turn.
We are hooked!! We'll be back but with a much bigger motor with a lot more HP, capable of a lot more Rs. Next time with the A-motor, we're knocking on the door of 130. Stay tuned for changes and upgrades to the Squarsche in the upcoming months. . .
The volunteers of the USFRA put on one hell of a great event!! I can't thank them enough for all their efforts.
Here's an action video of one of our runs.
https://www.youtube.com/watch?v=tPFrJx8GY6w
Josh having fun early on the last morning.
https://www.youtube.com/watch?v=Qo9LuAI9ghA
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Nate, your car ran so smooth. Awesome man.
Cool videos too.
I had a 71 Ranchero that colour but over here they come with a 351C.
Thanks for sharing and greetings to Josh.
You guys did great. :cheers: :cheers: :cheers:
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Saturday was a day of good news and bad news. . .
Good news: The new race motor is in and it sounds GOOOOOOOD!!
https://youtu.be/KUBwnmRAI0Y
Bad news: about 1/2 hour after me and my buddy got it stuffed and hooked up, we found out that World of Speed 2015 has been canceled!! :evil: :(
Back to the good news, . . . So I've got a full year to get it dyno tuned and fully broken-in. :wink:
I'm gonna raise the back up about 3/4" just to give a bit more room for the sump.
(http://images.thesamba.com/vw/gallery/pix/1397802.jpg)
(http://images.thesamba.com/vw/gallery/pix/1397801.jpg)
(http://images.thesamba.com/vw/gallery/pix/1397800.jpg)