2.0 KCC 356 Speedster - www.356speedster.co.za

[flatfourfan]

So some work today. I was able to replace the bent and busted rear frame rail. I had to cut out 3 sections and take everything over to the bench and then piece it back together again and replacing the busted section in the process. I reinforced the frame rail by welding on some flat bar stock on both sides as well as putting a lip on the top and bottom to give it some more strength. Overall I'm happy with the repair and gave it a lick of primer and called that repair a day.

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I had to cut out all of the fibreglass from the frame rail to the body as it was pretty much all crap, I'll redo this in the next week or so and then get some decent bolts to attach the body to the body and frame. The whole rear section is done with crappy pop rivets and it makes for a very loose rear end.

Then came time for the radiator, I worked it out that I had about 2 inches to play with with the depth of the scoop as I had the battery box there before and in the 5-6 months that I was driving around with the box there, I never hit it against anything and the suspension was at its lowest point.

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The radiator will be mounted flush with the floor and then the scoop will sit below.

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I also started cutting out the area behind the radiator as I want to make a curved section that will expel the hot air under the car, the last thing I want is to push all that hot air onto the brake master cylinder, or under the gas tank. The next load of fibreglass work will involve boxing in the radiator and making a removable panel so that the radiator can be removed and serviced. The radiator frame will be bolted to the body as I have to be able to remove it otherwise the A-frame won't fit on. Then I've already started work on my new fuel tank, stock bottom end, but with a curved porsche style top that sill sit higher, but will be moved far back and the fuel filler will be up top so that I can get my spare wheel in the area between the radiator and the fuel tank.

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Overall I'm pretty chuffed with todays work, the civic radiator is small and compact and the fan unit is actually bigger than the radiator, but keeping the OEM unit allows me to use the cowl and therefore makes buying parts easier than having one off parts on the car.

[flatfourfan]

Time for an update.

I had to get the radiator mount out of the way, so that the water pipes could be installed so that the mounts for the fuel lines could go in as well. Big request with the radiator was that it had to be removable, because I'm still moving the car around with an a-frame and it was going to foul with the radiator.

The radiator mount is damn sturdy and this is actually version #2, because I wanted about 40mm of it sticking out so that it be able to take as much advantage of the air that's in front. There is going to be quite a lot of fiberglass work up front to clean it all up, but I see that as very minor.

First was to mock up the frame, 3mm 20mm flat bar was used so that I could follow the contours of the speedster, so that it would look neat.

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Luckily I was able to fab most of the frame while it was mounted on the car, so it made for a nice clean set up and everything actually fitted 100%.

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The radiator set up fits in nice and clean and up front there will be enough place for the spare wheel jack and the other side will be for the tool pack.

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Then the plan of action will be to pull the fuel tank and then have the new fabbed one mounted further back closer to the firewall that will allow me to mount the spare wheel back up front. But I'll probably wait until the car is running fine and I have the bugs sorted out.

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Stay tuned, things should pick up some speed now.

[splitfan]

Looking good Gary! The end is in sight! I am ready to contribute to the watercooled fund when you fitted your new speedo's

[flatfourfan]

shouldn't be too long now as I want the last of the fab work done by the end of the month and that includes all the fibreglass work as well and I'm planning on doing the dash pad as well as the dash pods.

[flatfourfan]

Only had 2 hours to work on the speedster today as my father in law wanted to go play 18 holes, so who was I to say no?

I did probably the one job that I was dreading from day one, cutting the lower section of the nose. I've found a lot of pictures of the PGO speedster and in order to allow as much air to the radiator without having to drop the radiator too low. I measured this sucker about 30 times before doing the initial cut and yeah it was still nerve wrecking. The initial cut was the worst...........

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Even with the bumper on the lowest setting, it covers it 100%. The bumper will also be trimmed and cut.

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I'm also going to redesign my radiator cradle as I want it a bit more further forward and also a bit more slanted so that I'll be able to get as much of the radiator getting direct air. I also won't have clearance issues with the nose and radiator. I did try and slant it down by about 20mm off vertical axis, but now I won't be able to remove the radiator and fan without taking the cradle out, so I'll have to work around that next weekend, luckily it's only changing the two lower sections on the frame.

radiator slanted.jpg

I've also started work on my spare bumper, trim the lower sections as I won't need them anymore as I've designed a flat bar frame section for the front bumper that is about a million times better that the normal bolts and that came from KKC. I also want to mount bumper overiders and spot lights at some stage, so I want a sturdy bumper that won't give me any flack.

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Next is Fibreglass time.........so the front can now be framed up, the scoops made, the dash pad finished as well as the new porsche gauges.

[Firebird]

Looking good dude.

I don't know how you worked up the courage to cut away the front

But it turned out well ~ phew

[flatfourfan]

Looking good dude.

I don't know how you worked up the courage to cut away the front

But it turned out well ~ phew

Initially I was thinking, bugger do I really want to do this? I started cutting small sections from the inside of the nose and it was looking terrible, that's when I drilled 4 pilot holes from the back and then laid some tape, used a diamond cutting blade on my baby grinder and the cut is as smooth as silk.

That's the nice thing about fibreglass.....If I screwed it up, then it's a simple case of fibreglass it up and do it again, I'm not too phased as I'm only planning on painting the car when I know that I have zero cooling issues and I've done pretty much every body mod that I wanted to do. The list of mods to the body is long.

Next on the list is the duct work mock up, will be wood initially to which I'll make a mould from fibreglass which will close up the hole in the floor and also box in the radiator and then there will be a trumpet reduction intake thingie that will mount to that, that will peak through the bumper a bit. Painted the same colour as the car so it'll blend in. I'm making it in two peices as in case it takes a knock, I'll be able to remove it and easily/ quickly repair it.

[Rabid_ant]

i'm liking!!! Good to see action.........

[Bugger]

i'm liking!!! Good to see action.........

Hi Lurker

[flatfourfan]

Kev.............buddy, good to see that you're still floating around.

So yesterday I was able to get some time to shoot through to GILO in jhb for the flywheel and adapter plate as I have been using WIllems for mock up purposes and he's gonna need it back pretty soon.

I can't say enough nice things about these guys, amazing set up that they have there and the workmanship is top notch. Total price for the adapter plate and flywheel is R2260-00.

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I've had to change my plans a bit though as I'm not 100% happy with my water lines. I'm a tad nervous about them rubbing on the body, so I've got to modify them a tad this weekend if I get a chance.

Next on the list is to pick up my wiring harness, ECU (unlocked and chipped from City used spares) and also my old 3 bar fuel pump. Once I have the pump, I can finish off my new hardlines for the fuel system. Last thing to buy will be the engine. Finish date is set for the end of April.

I made a deal with my wife where I'll build my daughters a garden dollhouse from left over wood that I had lying around and she'll buy me a motor. Awesome deal, the catch???...........the dollshouse has to be done first. Bummer, hoping to have that sucker done next week though.

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[buggyfan]

did youn get all the info from gilo as to which clutch to use so you dont sit with this problem>>>>>>>>>> http://www.aircooledvwsa.co.za/viewtopi ... lo+adaptor

[flatfourfan]

I did have a chat with them, but it's pretty straightforward. I decided to buy a clutch kit elsewhere as Gilo were a tad more expensive for the same thing.

1.8 flywheel and adapter with a stock VW 1.8 clutch kit for a 2.0 motor to a stock beetle gearbox. No spacer/ bus starter needed, standard beetle starter works fine. My buddy Willem has done one before on a beach buggy using the same set up and it works fine.

[buggyfan]

cool

if i may ask ,how much was the clutch as Steve still has the clutch kit for sale from the post above

[flatfourfan]

cool

if i may ask ,how much was the clutch as Steve still has the clutch kit for sale from the post above

I bought a brand new velo clutch kit for R700 (mates rates)

[flatfourfan]

Finally got the radiator support sorted and finalised. It only took about a month of small modding, trimming, welding and doing it all over again about 6 times. But she's in and she fits perfect. So much had to be taken into account and in the end I'm more than happy with the results.

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This weekend if all goes well, I'll be able to get some more fibreglass work done as well as the lower box section has been done, but I'm saving that for a treat once the radiator has finally been mounted.

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This sucker has taken ages to perfect and it has been holding up a lot of work that has been backing up.