Idle control and maybe intake leaks, how to for swapping in a 52mm Vanagon throttle body Options

[VaccaRabite]

I broke the plug to my idle control valve. I bought a new plug housing. Easy. But I’ve had a devil of a time finding the right socket pins for the housing. Several weeks have been stalled waiting for 80 cents worth of pins that show up and are the wrong size.

So, knowing the 914 has to drive next weekend, I went full DACO and soldered a pigtail of wires into the ICV and then crimped them into place.

About to find out if it works, and will continue to work for a couple weeks while I sleuth out the right sockets for the plug Wish me luck!

Zach

[VaccaRabite]

The GoWesty unit is pretty awesome, and converting it was a piece of cake. This unit is 52mm at the butterfly. This makes it larger then the 1.8 914 TB (45mm) and larger then the 2.1 Wasserboxer TB that people usually swap over (50mm). Also, this unit is MUCH EASIER to swap then the 2.1TB, had double bearings for the throttle shaft and is BRAND NEW not 40 years old and worn out.

Here is how I went about doing it:
(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433145.1.jpg)
First thing to notice for these units: Stock 1.8 L-jet in on the left, GoWesty on the right. THE FLATS ARE THE SAME! The throttle arm on the GoWesty is angeld all wrong for a 914, so off it must come. We are going to cut up this nice shiny new piece of metal. We will need bits from the 1.8 throttle - in particular the arm for the barrel nut.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433146.2.jpg)
Mocking up the old arm, you can see it takes the PERFECT angle on the new TB, versus the bus arm that is far too low. But the bus arm has the throttle stops, so we don't want to eliminate it completely.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433146.3.jpg)
Here are the cut lines. We preserve both throttle stops on the GoWesty piece, and just take off the nub on the 914 L-jet piece.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433147.4.jpg)
Boom! perfect! Lower arm controls the throttle stops, upper will attach to the throttle. I also preserved the lug to mount an aux return spring since the GWesty unit has a weaker spring and may need help.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433147.5.jpg)
another view of the top put back together.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433147.6.jpg)
And mocked on to the plenum. Perfection.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433148.7.jpg)
lower half of the GoWesty unit. This is where things get really awesome. I have already remove the Vanagon 2 position switch from the shaft. Look at those nice threaded holes. I wonder....

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433148.8.jpg)
the shaft is 4.5mm too long for the Microsquirt TPS to fit without a spacer. So I marked it and cut it to size. I DID NOT remove the throttle shaft from the throttle body, just cut it in place. Still really easy.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433148.9.jpg)
BOOM! The TPS was able to use the two drilled and tapped holes on the GoWesty plate. Its almost like they planned for this kind of modification.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-1435-1620433148.10.jpg)
and here we have the ONLY sticking point. My friends at the shop up the street got a little too aggressive with the expander die, and took the intake horn on the Plenum from 45 to 55mm - but they left me no taper to go into the TB. So I am slowly tap-tap-tapping the opening with a small engraving chase hammer and putting a taper back into the opening. I MAY need to trim it a little too. But I'm going to slowly keep tapping until I reshape the opening to 52mm and see how the TB fits. Even the work that I have done in this picture has helped a TON.

I am not planning on using the rubber gasket, but using a RTV gasket sealant instead.

Zach