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

[aircooledtechguy]

This weekend I turned my attention to the steering since I’m awaiting a set of camber plates assemblies from Chris @ Tangerine Racing (www.tangerineracing.com). The goal was to finish the welding on the front mounts from last weekend (since I ran out of welding gas) and get the front-end ready to accept the Porsche rack & pinion steering gear. I fell a bit short, but made fine progress nonetheless. It is surprising even to me just how much time this stuff takes to do.

Since I’m going all Porsche on the front suspension, it’s only natural to upgrade to a Porsche R&P set-up. So I acquired a nice factory unit and upgraded it with Porsche 930 turbo tie rods which is a popular upgrade to add a more positive feel and preciseness to the steering.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789111.1.jpg)

The column chosen is from a '73-on Super Beetle. I want to have a modern dual stalk column so I can get the wiper switch off the dash and onto the column and have a steering lock. This is also a dual bearing column which uses a similar intermediate shaft as the Porsche unit in the photo. Of course the column mounting will have to be heavily modified for the type3 as well as shortened considerably along with the intermediate shaft in order to work in the Squarsche.

Since the lay-out of the car and pedals prevents me from installing the R&P unit in the same location as a Porsche, I had to mount it above the master cylinder. This, actually, is a good thing since it will enable me to attach the tie rods from the top of the pitman arms rather than from the bottom and thus avoid bump-steer issues. To attach them, I will be modifying them with a VW Super Beetle bump-steer kit. As luck would have it, the Super Beetle tie rods have the same length and taper as the Porsche tie rods, so a cheap $15 kit is all that’s required.

I began by locating the center and where the steering shaft assembly would pass through the fwd firewall. Then I used a 4” hole saw to make the hole.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789112.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789112.3.jpg)

The rack could have been installed as is, however, it would be too far fwd by about 1.5” so the tie rods would be swept too far back (more than stock) and cause more bump-steer issues. So I had to set it back. So I traced a pair of lines 3” apart and carefully cut a slot lengthwise in the front firewall so it would be in the correct position.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789113.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789113.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789114.6.jpg)

Then used half a 3” muffler pipe to box-in the section and make it all strong again.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789114.7.jpg)

The pipe actually intersects 3 pieces of metal since the bottom half is a double-wall.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1367789115.8.jpg)

This is actually stronger than stock now and will become stronger when I install the 4” piece of pipe to the center to make the pass-through for the steering shaft.

This is as far as I got this weekend. I was shocked at just how much time that took to get accomplished ; I burned the better part of a day getting the tube fitted and welded. . .

[scotty b]

quick reading resulted in a hasty post. Carry on (IMG:style_emoticons/default/smile.gif)

[PanelBilly]

Such creative workmanship. What's next?

[aircooledtechguy]

Got some new tires for the Squarsche today via Tire Rack. This aught to piss off the purists. . . :twisted: Staggered fitment; 205s in front, 235s out back. That should keep the rear-end under control. I just went with some cheap Sumitomos this time to get things going. We'll see how well they hold-up to the abuse and maybe upgrade to a better tire/compound in the future as funds allow.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368129429.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368129430.2.jpg)

I also took delivery of a set of camber plates from Tangerine racing. OMG are these things cool!! I'll be able to add up to 2.5 degrees of camber in the front if I want. So if I have a track day/auto-X, I can add more camber and improve the handling. So I'm in the process of making the shock tower templates now so I can get those fitted and get this beast back on it's feet.

[carr914]

Those Sumitomos may be Cheap, but they are Great Tires

[bozo914]

(IMG:style_emoticons/default/agree.gif)

[aircooledtechguy]

Those Sumitomos may be Cheap, but they are Great Tires

That's good to hear. They got pretty solid reviews on-line so,. . . I figured that for the price, even if they last only one year, they will be O.K. This has been an expensive week for this project with having to buy wheel spacers, camber plates and tires, but I need everything now in order to proceed.

[carr914]

Those Sumitomos may be Cheap, but they are Great Tires

That's good to hear. They got pretty solid reviews on-line so,. . . I figured that for the price, even if they last only one year, they will be O.K. This has been an expensive week for this project with having to buy wheel spacers, camber plates and tires, but I need everything now in order to proceed.

They are very good, I used them as Track Tires on my S2000. The rest of the Sumitomo line is Junk IMHO

[aircooledtechguy]

My attention today was the steering. I needed to fit the Porsche R&P steering unit, fabricate the bracket to mount it. Then shorten a Super Beetle steering column (yeah, Supers ARE good for some things (IMG:style_emoticons/default/laugh.gif) )

I first had to modify my 4" hole that I cut earlier so that the tube would not be in the way and so that the input shaft would be in the right position when mounted. Then it was tacked.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368318423.1.jpg)

The mount was next. Spent some time getting this made so it would be strong and fit right. I'm happy with how it came out.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368318424.2.jpg)

Then I needed to shorten the Super Beetle steering column. I used a Super column for 2 reasons.

1. It has a bearing at both ends which I needed.
2. It is a dual stalk column, so I'll be able to move the wiper switch off the dash where it's a total PITA to use and right where it should be; within fingers reach. This will also enable me to use a delay wiper relay if I want to later.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368318424.3.jpg)

This turned out to be a really easy job. I cut about 1 foot out of the outer tube. I then trued-up the ends on my 12" disc sander and removed the paint. Then I tacked it together and finished welded it.

Once that was made I could take measurements for the steering shaft to ensure it was the right length. I used a tubing cutter to cut it apart. This makes a nice clean and straight cut. Then on the disc sander, I beveled the ends at a 45degree angle since the metal is thick. This allows for proper penetration when it's welded. Then I clamped it into my vice tubing clamps to ensure it was held straight and tacked it. After verifying that it was straight and worked i the column, I finish-welded it together.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368318425.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1368318425.5.jpg)

Another thing I got accomplished this week in preparation of today, was to remove the dash vents and get those back to working condition though they are still out. And I modified the wiper assembly so I could use the late wiper pivots and arms. I made some custom wiper arms out of late bus arms since the type3 units are harder to find.

[aircooledtechguy]

So,. . . I FINALLY got a Saturday to get back to the debauchery and I made some good progress.

First, I have to confess that I’ve been putting off the purchase of a plasma cutter for way too long. So after my last update, I was so tired of doing all this fabrication the hard way that I finally man’d-up and bought one.

FYI: I bought one of the cheap Ebay specials after reading reviews on-line. I got a Cal Electric Cut-50. It’s yellow and everyone knows yellow tools cut stuff better, so. . . (IMG:style_emoticons/default/lol-2.gif) For being $320 delivered to my door, it works pretty darned good and has saved me a ton of time already. I think of all the time I wasted fabbing the camber boxes and other parts and . . . So to recap: after 80% of the fabrication in DONE, I decide to make things easier. . . (IMG:style_emoticons/default/rolleyes.gif) Well, I’ve NEVER been accused of brilliance or good timing, so all I can say is, better late than never!! ANYWAY!! Back to the debauchery. . . (IMG:style_emoticons/default/happy11.gif)

VW pedal assemblies are great for driving to and from work and stuff, but they are just too tall and un-ergonomic for any kind of performance driving where the right foot needs to do heel/toe duty. So to bring the pedals to a better height, I cut them down 1.5”. Now before some cry, “Hey, that’s gonna make the brakes harder to apply!” Not to worry, if I find the brakes are too stiff, I’ve already got a secret weapon in the arsenal in the form of a Porsche 996 master cylinder and matching power brake booster. I may not actually need this since I’m gonna have Porsche 944 brakes out back and 911 in front running a Porsche 911 MC, but just in case, I’m prepared to make changes to the power 996 unit.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.1.jpg)

I also ordered and received a very hard to find set of female, metric M14XM1.5 heim joints to replace the factory Porsche tie rods. Since I had to move the R&P up a couple inches, I could not use the stock tie rods. Normally they mount from under the pitman arm, but mine will have to mount from the top or massive bump-steer would be an issue (similar to how you have to flip them in a lowered super beetle). I found these in Europe and they fit the bill perfect. I’m still waiting on the 14mm drill bit so I can’t finish the job. Once I ream the hole 14mm, I’ll make one long spacer that goes ¾ of the distance they will need to be and add shims for the remainder so I can have some tuneability in the bump-steer area.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.2.jpg)

The rest is all getting the Squarsche back on it’s shoes.

I finished the camber boxes , so I had to ensure the holes on the inner fenders were large enough for the shock struts could fit through with the dust covers. So I marked them out on a Sharpie and cut them with the Plasma cutter (Damn I love that thing!!)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.3.jpg)

After stripping the paint away from the areas the camber boxes would mount and priming everything with weld-through primer, I sparked up the MIG welder and tacked them in place. Then after careful measurement, I finish welded them in place. They’re permanent now, like it or not. (IMG:style_emoticons/default/shades.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.4.jpg)

Once they were cooled-off, I assembled the struts with the dust covers and the Tangerine Racing mono-ball strut mounts and assembled the struts for a test fit. Like a glove!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.5.jpg)

The Squarsche is now back on all for wheels for the first time in over 3 months!!! There’s still a lot of work to do, but it’s nice to know jack-stands and blocks of wood are a thing of the past!! If I listen closely, I hear winged H*nda fart-cars scrambling to get their passports stamped so they cam make a quick escape before the embarrassments begin. . . (IMG:style_emoticons/default/happy11.gif)

The first pic of it back on the ground. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.6.jpg)

I hung a fender to see what I could be in for. It hides everything. It’s nice and stealthy; just a wagon with new wheels rolling down the street, really. . . (IMG:style_emoticons/default/happy11.gif) Sorry Rich; the wheels are staying; get used to them. (IMG:style_emoticons/default/av-943.gif) If my plans didn’t call for wheel spacers front and rear, I could probably roll the rear fenders with my fender roller and be finished, but I have much more debauchery planned. Stay tuned. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.7.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1371958115.8.jpg)

[McMark]

So sick... (IMG:style_emoticons/default/drooley.gif)

[NORD]

Nate; Room for a V8 up front? Pretty Cool.

[sixnotfour]

Nice ..17's vs 15's youre on it.. (IMG:style_emoticons/default/popcorn[1].gif)

[BajaXJ92]

I love this build! (IMG:style_emoticons/default/wub.gif)

Jealous! (IMG:style_emoticons/default/beerchug.gif)

[Mike Bellis]

Very Cool!!!

[914werke]

Ba-LING!!! (IMG:style_emoticons/default/biggrin.gif)

[montoya 73 2.0]

Everytime I read this thread, it makes me want a Squareback again! My first car way back in 1986 was a 65 variant S. I loved that car. Good job Nate!

[jaxdream]

You need a custom emblem on the back ...VW-T314!!! (IMG:style_emoticons/default/piratenanner.gif)

Jack

[JawjaPorsche]

I really admire your skills. Awesome build. (IMG:style_emoticons/default/beerchug.gif)

Had a 68 Fastback when in college. Traded it for my new 914 in 1973. Had some good times in the Fastback.

[aircooledtechguy]

Ba-LING!!! (IMG:style_emoticons/default/biggrin.gif)

Isn't a requisite for that chrome twenty-fo's?? (IMG:style_emoticons/default/confused24.gif) (IMG:style_emoticons/default/lol-2.gif)