Sasquatch Part III Audi 1.8t transplant..., PCV upgrades finally... Options

[Mike Bellis]

I have A.D.D. I admit it. I also can't leave well enough alone. I got really motivated by Andrew Dalen and seeing a 914 with Subie power driving to WCR12 from Idaho. What a beautiful car...
I stumbled on a steal of a deal for a 2001 Passat 1.8t, Audi ATW engine and 5 speed transaxle. Long story short and here you go. New engine cleaned and ready for fab time. The exhaust and turbo have been removed before power washing.

Here is a link to Part I
http://www.914world.com/bbs2/index.php?act...=0#entry1396734

Part II
http://www.914world.com/bbs2/index.php?showtopic=172455




Here is the challenge. The transaxle. Either I fab an adapter, Fab an axle to take 1 Porsche CV and 1 Audi/VW CV or Replace with Boxster tranny, that will: Bolt right on, Shifter is cheap and available and requires less fab time. I'm leaning to the Boxster due to the 100mm Porsche CV flange. The Audi is 114mm.



This is whats left of the wiring after the car gets gutted. The ECU and gauge cluster have a symbiotic relationship. They work together and have to stay together to run. It looks like it will fit nicely into the stock location. I may have to adjust the column lower and build an trim ring around the cluster.

[Mike Bellis]

Been taking it slow on the conversion. Here's something...

I found a Boxster shifter and cables on ebay super cheap. The hard part to find is the linkage on the tranny. I found one at a local recycler way too expensive. So I ordered some 10mm balls ($4) and with some stuff on hand fabricated the stuff I needed. I had some heim joints and rod, all the bits you see.

Since this is an Audi tranny and not a true Boxster, the threaded boss on the case for the factory pivot is not drilled or tapped. I had to fab a new pivot point and re-align the geometry a little. I used the factory linkage mounting holes to build from and picked up a mount in the rear to carry the pivot point. The pivot I used is a ball bearing adjustable bell crank from a 6-71 blower; Very stout. 3/8 rod and 1/8 flat stock make up the rest. All parts went through a heat treatment with a dirty oil bath.

Here's the working prototype. I plan to move the Neutral gate cable more inboard to reduce the angle a little. This thing shifts super nice! I have 2-3mm of end play on the shifter. I used the Porsche design to inspire me since they did all the R&D for me. I can hardly wait to drive a 914 with a modern transaxle.



Second Gear





I designed the cable bracket to accept the factory locking design. Need to maching deeper and move the divots for the locking clips.



I used 0.75"/0.120" DOM to make the shift bracket. My ghetto hardening gives it a cool blue/black color, stiffens everything up real well.



Re-aligned cable angle