OT: Working on my shop car, The wagon Porsche never built. . . Options

[aircooledtechguy]

How much room will there be between the fan pulley and the muffler? Are you concerned about cooling the engine with hot air?

Just curious as you have obviously thought this through.

I'm using a custom steel air guide that replaces the factory rubber bellows on the type-3 that brings the air from the rear duct directly into the fan. I may add a second skin 1/4" off the center section of the muffler if I find it's too close and transfers heat but I don't think it will be a problem really.

What I may do to monitor incoming cooling air is to add a temp sensor and integrate that into the Megasquirt dash so I can monitor it directly rather than assuming heat by watching my head temp gauge which is a very indirect way.

[aircooledtechguy]

I spent Saturday hold-up here at the shop and made it my mission to get the Squarsche's new exhaust header built and tacked together. The goals were to have a header that (1) was equal length (or darned close), (2) not have any part of it hang down below the sump and cause ground clearance issues and (3) to not interfere with access to the engine (like the valve covers, etc). I began by getting the collector positioned and tacked into place. Then it was a matter of getting all the other pipes to fit from their respective stubs to the collector while adhering to the rules.

I began with cyl. #2 since this was the longest run and the most direct shot, then I did #1. I needed those two to fit between the bell housing and the case where there's a bit of room and it's there that I installed a slip-joint for expansion and to ease in installation & removal.

Cylinder #3 & #4 were the most difficult since I also wanted to ensure they didn't interfere with the valve cover on that side. and because of that, it's easy to run out of room for tubing. Cyl #3 was the most difficult but I got it all to fit in there and be smooth so I'm happy with it. I hope it sounds good. . .

Here's the system all tacked together and ready for finish TIG welding:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387831617.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387831617.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387831617.3.jpg)

With the muffler:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387831618.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387831618.5.jpg)

[wingnut86]

Ummm, Mongo REALLY want one!!

[Java2570]

(IMG:style_emoticons/default/beerchug.gif) that looks great! Can't wait to hear what she sounds like!!

[aircooledtechguy]

I came in a little early this morning so I could put a nagging issue to rest. Since going to Porsche 5-lug wheels, I have not had a real spare or one that I would call handy. The only affordable type I could find was at a local Porsche swap that was from a Porsche 944. I recently priced a single early 911/912 wheel in 15x4 .5 and that ain't happening!!!!!! Holy crap guys are proud of those things!! While it could do the job alright, it's truly a VERY temporary spare that has absolutely no re-enforcement chords of any kind and basically no tread either. The other issue is that it's designed to be stowed in the deflated position which would necessitate carrying an air pump. . . Another thing to haul around everywhere. To make matters worse, the rim was 5" wide which made it a super snug fit into the tire well.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387924903.1.jpg)

Last week on a whim I measured the ID of the hoop on both rims and discovered that they were exactly the same. (IMG:style_emoticons/default/idea.gif) (IMG:style_emoticons/default/happy11.gif) So this morning I carefully cut the welds that hold the wheel centers to the hoops. After prepping the Porsche center and the 4.5" VW hoop, I tapped the center into the hoop.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387924903.2.jpg)

Then I bolted it to my front hub and trued the hoop on the hub by spinning it while a piece of chalk showed me the high points. Once the chalk made constant contact, I knew it was true so I tacked it in place. Then I carefully dismounted the rim and finish welded the Porsche wheel center to the VW hoop. 'Cause I know someone will say something; YES, the tire is a junker and was deflated with the valve core removed!! (IMG:style_emoticons/default/stirthepot.gif) (IMG:style_emoticons/default/welder.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387924903.3.jpg)

Viola!! A spare that is full size, can be aired fully, can be driven hundreds of miles if need be, is the same diameter as my Porsche wheels/tires and fits like stock in the tire well. Surprisingly, it only took about an hour to complete. Now I'll have to send it out for powder coating when I have a bunch of stuff get done.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387924903.4.jpg)

Before it goes in the scrap pile, does anyone want a 4-lug VW rim 5" wide with a folding Porsche spare tire?? (IMG:style_emoticons/default/shades.gif)

[rick 918-S]

Great solution! Way to think out of the box! (IMG:style_emoticons/default/aktion035.gif)

[KELTY360]

Since this build is obviously out of this world it begs the question.....what color is the sky on your planet?

(IMG:style_emoticons/default/pray.gif)

[aircooledtechguy]

Since this car will see a race track from time to time, the fenders will be going on and off quite a bit for maintenance and adjustment track side. So I figured replacing the stock screws and installing dzus fasteners would be a good upgrade. Luckily I have a sprint car supplier showroom near by (www.speedmart.com) so I hit them-up for some aluminum dzus parts.

I had to first slightly enlarge the holes in the fenders with a burr.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748714.1.jpg)

One thing that always slows the process is drilling the holes for the spring catches in exactly the right spot. So after pondering the problem, I came-up with this steel template that centers itself in the hole via a cut-off bolt and then you just drill through the guide holes on either side. Viola!! Perfect placement and it only takes about 2 minutes to drill ALL the rivet holes for the springs!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748714.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748715.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748715.4.jpg)

Rivet the springs in place:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748716.5.jpg)

Then fit the fender and fasten the dzus fasteners with a 1/4 turn "click".

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1389748716.6.jpg)

Now I'll be able to remove a fender in about 30 seconds rather than several minutes.

[KELTY360]

Way cool!

[NORD]

Kelty; I. Was down to Nate's shop a few weeks ago. That square back is going to be really different than stock. I'll let Nate share that when the fenders are on. (IMG:style_emoticons/default/driving.gif)

[aircooledtechguy]

Thanks Marc. I can't wait to get this back on the road and go driving. Crossing the center line (IMG:style_emoticons/default/headbang.gif) shouldn't be an issue with 255/40/17 tires stuffed in. (IMG:style_emoticons/default/driving.gif)

Kelty; I. Was down to Nate's shop a few weeks ago. That square back is going to be really different than stock. I'll let Nate share that when the fenders are on. (IMG:style_emoticons/default/driving.gif)

If I haven't already pissed-off the stock-nazis in the VW community, my fender mods should send them to the hospital. (IMG:style_emoticons/default/happy11.gif) At least my mods will all be functional. . . I'm keepin' a tight lid on this until they are finished. . .

[audio_file]

This is really looking great Nate! Ive got to get up there and visit again soon... (IMG:style_emoticons/default/beerchug.gif)
chris

[Dr Evil]

For you, Nate:

Ego stroke, ego stroke, ego stroke (IMG:style_emoticons/default/smiley_notworthy.gif)

Not that you seek it, but you deserve it. Wish we were neighbors (IMG:style_emoticons/default/smile.gif)

[aircooledtechguy]

I had an hour or so between jobs today and decided to tackle the passenger outside mirror. The side mirrors on my '67 while functional look like such an afterthought and I always hated them. So off they went and I decided to use a period Porsche mirror instead. I wanted something that looked "right" on a Squareback but also wanted something that was fold-able for high speed runs. IMHO the Porsche 914 flag mirror looks PERFECT on a Squareback.

So I made a quick template out of cardboard, transferred it to 20 gauge metal cut and bent,. . . BAM!! The new base:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341418.1.jpg)

Then I had to mark out where the anchor nuts would be recessed into the door and then drilled them out with a step drill. Then it could lay nicely on the metal.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341419.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341419.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341419.4.jpg)

After that the base got welded in place and the new mirror attached for a test fit. PERFECT (well in my mind anyway (IMG:style_emoticons/default/happy11.gif) )

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341420.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392341420.6.jpg)

[aircooledtechguy]

So late yesterday, I pushed in my derelict '69 Square that I've been keeping around for parts and other stuff, so I could finally do some of that "other stuff". (IMG:style_emoticons/default/laugh.gif)

So I threw it on the lift and with the help of air tools and other implements of destruction, 5 minutes was about all it took to separate the rear suspension sub-frame from the car.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518393.1.jpg)

My goal for this weekend was to turn a 3" round block of Teflon into solid rear suspension sub-frame mount bushings (that's a mouth full). After taking careful measurements off my '67 Square, I determined that the body of the bushings would need to be 1.5" tall.

Just to refresh those who may have missed this back a couple years ago, when I installed the Porsche 923 (915 series) 5-speed trans, it was discovered that in order to NOT have to cut a pocket into the back seat area (and the seat), I would need to lower the suspension. Thus lowering the engine/trans in the process. Well it worked fantastic and the center of gravity was lowered in the process adding to the handling of the car. The spacers that I had previously made were more of a "run what you brung" type of deal made with stuff I had at the shop at the time. They work fine and were perfectly safe, but I want something race worthy since I'm gonna be taking this thing to future tack events and and have to pass tech inspections from lots of different sanctioning bodies.

Anyway,. . . I needed access to the profiles of the cars body and to the sub-frame since they kind of lock in place to ensure that they lock tight in the future. So with these exposed, I went to work.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518394.2.jpg)

I began by cutting 5 two inch pieces of Teflon. This would give be the 1.5" I needed for the spacer and an additional 1/2" that will fit into the sub-frame. It's easier to leave them a bit long and then make them precise on the lathe. Teflon is really easy to work with. If there are any REAL machinists in the house, please avert your eyes from the horror that follows. :wink: This stuff ain't goin' on an aircraft, but it WILL fly!! 8)

Chucked-up and finished the last aft mount.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518394.3.jpg)

The completed set:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518395.4.jpg)

Comparing the old and the new:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518395.5.jpg)

Fitted to the sub-frame:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518395.6.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518395.7.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1392518395.8.jpg)

[r_towle]

What are your plans for that rear sub frame once you are done.

I might want that for a project.....

[aircooledtechguy]

What are your plans for that rear sub frame once you are done.

I might want that for a project.....

I'm actually going to be using parts of it for another project this summer. Sorry.

[aircooledtechguy]

As the fender widening continues in earnest, some other stuff has gotten done. I removed the ugly rear calipers and rebuilt them. Since it's a proven fact that red calipers not only make the car faster, but also helps you stop better :roll: , I went with red powder coat. . . (IMG:style_emoticons/default/laugh.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1394847979.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1394847979.2.jpg)

The fronts are in-work as I type. . .

[jaxdream]

Single piston sliders from what vehicle ??? RRRReeeeDDD !!!!

Jack

[aircooledtechguy]

Single piston sliders from what vehicle ??? RRRReeeeDDD !!!!

Jack

They are stock Porsche 944 N/A for the rears and I'm using 911 front struts/rotor/brakes.