Revival of the fittest - new buggy build

[Pine]

Hey Airpower, that looks SO GOOD!!!

Can't wait to start on my own buggy..

[AirPower]

Are those audi calipers?

VW GTI mark II Eben

Thanks Pine

[AirPower]

Some more photo's - time to work on the buggy is in short supply, but I now got the standard motor inplace, but still need to get it started.

Here's an update on the fanhousing:

Fiberglassed the pieces together.





Fiberglassed the inside aswell.



Then sanded it down a bit (needs some more sanding to get it smooth)


On the motor it looks like this -



Also installed the Golfie FI fuel pump - had to modify the petrol tank outlet aswel (bigger dia pipe).





The 2nd petrol supply pipe is running in the square tubing along the side of the buggy with the main electrical wires on both sides. These will be covered by the side fiberglass panels.



So things are going slowly, but at least some progress is made.

Mario

[AirPower]

Installed coil-over front shocks, still plan to add some weight to the front - don't know how yet, maybe lead.

How do like that spring compressor? Home made junk, but it did the job. There's always a plan that can be made.

[AirPower]

Here's some more updated info. I can't believe how fast time flies - I was hoping to have the buggy running by now with the std 2,0 liter motor, but had to back-track an enormous amount - the fuel supply still is a huge headache. I've now chucked out the electric pump and BMW fuel filter/regulator. The people I bought it from (Bosch dealer) was just messing me around - I don't know who misunderstood who, but I could not get the fuel pressure down far enough for the carbs. They kept on leaking fuel and that's not only the Weber DCD's, but also the IDF's. So now I've installed the Facet fuel pump (should have done that in the first place) only I don't know if it will be able to keep up with the turbo once installed, but I'll deal with that when the time comes.



Then....... the brakes. Someone mentioned somewhere that when installing 4 x disk brakes on a Beetle, you need to change the master cylinder. On my car that is absolutely the TRUTH. I thought it would work with the std master cylinder, but the fact is - the brakes were gripping the disk ALL THE TIME. Not so that you cannot move the car, but enough for it to be noticeable. With the drums I could easily move the car around, pushing it while steering, but with the 4 disk brakes it was very difficult to move, let alone steer while pushing. So I've had to do a master cylinder change as well.



That's a duel circuit master cylinder, bought at the local dealer (he says it's for "early bus"). Had to do some re-arrangement of the brake pipes and shorten the push rod, but hopefully this will sort out the brakes. I've not tested it yet because the clutch cable was also found to be too long - so once THAT'S sorted out the pedal assembly can go back in.

At least the motor is running - I've started it up and the home-made fan etc seems to be holding up and cooling well. BUT (there always seems to be a but) The fan is spinning too fast. I will have to reduce fan speed. It blows an enormous amount of air just off idle and up to 3000 rpm, but just by listing to it, it scares me to get too close. I'll post a video soon.

All the best
Mario

[Dutch_Diver]

Nice update Mario.....I hope you have some smoother sailing going forward....

[AirPower]

Finally able to drive it around a bit. This is only the std type 4 - 2,0 liter motor. Timing is still not spot-on and the motor seems over-carbed with the weber 44 IDF's. The important things though - no wheel-hop and the clutch/flywheel seems fine. The brakes are cr@p though . I'll have to see what I can do about that.



This is the motor video'ed by aircooledwannebee. Fan looks to be holding up, but since there's no rev counter, I don't know up to where it revs.

[ZeroAxe]

So.... with the closing-up of the air inlet for the fan, just where do you get fresh air from??? Or am I missing something obvious?

[eben]

No filters either hey
Nice videos. You seem to have a similar muffler to what I have on my fastback.
BTW the carbs would actually work better with an air filter of at least velocity stacks to smooth the airflow.

[AirPower]

So.... with the closing-up of the air inlet for the fan, just where do you get fresh air from??? Or am I missing something obvious?

The air comes in around the alti. It's only closed in the back - but since this is an open buggy - I see no reason to pull air from the rear of the of the fan housing. Type 4 fan's direction is mos a bit different from the std beetle.

Eben - that muffler is shot - says "trade-in" in pink . That's only there to keep the noise down in the housing area where we tested it. Today the IDF"s will be exchanged for the DCD'S - we'll see how they run .

[eben]

Have you got vanes in the shroud?

[Blitzkrieg]

Awesome work! Thanks for the videos, keep them coming

[AirPower]

Have you got vanes in the shroud?

The vanes are there, but not ideal - I'm going to add 2 more on cyl 3/4 side when it goes onto the performance motor. Cyls 1/2 side is fine - fan blows to the right and down on that side.

Thanks Blitz

[Bugger]

Mooi man

So you have used the std Type 4 fan from the motor it looks like

[AirPower]

This is now one update I'm very proud of - brakes are SORTED. How - have a look.....



Drilled the manifolds for suction (both sides)- one-way valves installed.



Suction goes along the side (1/4 inch pipe)



Right upto this sucker. Braking with discs all-round and it feels like HEAVEN. No more wild pumping (that wording is there to get Vader's attention if he does a search) of the brakes and getting your ar$e off the seat to get enough weight on the pedal. Haleluja!
Works like a dream. Now I need a holiday more than ever!

Edit
That's a brake booster from a 1400 UNO in there. Is this the first ever Beetle with brake assist?
Edit
Mario