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

[Java2570]

Damn, that is bad ass! I should have come by the shop when I was out in Seattle last month!

[aircooledtechguy]

I had Josh trace out and cut the second inner fender well panel for the Squarsche today. He'll be doing a mirror image of what he watched me do yesterday on the passenger side.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1405528487.1.jpg)
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On the passenger side I marked and welded in the dzus anchors I bought from Speed Mart into the OEM inner fender well. This will act as an air duct to bring cooling air from the NACA ducts fwd of the rear wheel, over the rear wheel and straight into the OEM cool air duct at the back of the car. This will help to force-feed the fan at speed. I went this route rather than just switch to the later fender grills and *hope* enough air would find its way into the fan.

Since we're running at Bonneville, we had better be able to clean the ducts out after racing, so they are being held in with dzus fasteners. Here's my side:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1405528488.3.jpg)
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(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1405528488.5.jpg)

His side to follow and I'm sure it'll be better than mine. . .

[aircooledtechguy]

No pics today. . . Just verbage.

Had a couple days that disappointed me and ended up as wasted time, which I can't afford at this point with less than 50 days to go before World of Speed @ Bonneville. Anyway, progress was made on 2 fronts. . .

1. I got the inner fenders sealed for the NACA ducts to bring cooling air to the engine. This was huge. Originally, I had grandiose schemes of ducting from the NACA ducts to the inner fenders, however I had grossly over thought this. All I needed to do was to prevent air from traveling from the NACA ducts to the rear section of the fenders and attempted a fiberglass ducting system to make this happen. . . I lost a n entire day on this fiasco. A simple 6" wall prevents this and the "lazy air" will have no choice but to go down the duct over the rear tire and into the engine. Woohoo!! A HUGE burden has been lifted off my shoulders. . .

2. I now have brakes. Yeah, racing at Bonneville make brakes kind of the last thing you need to be concerned about, but it was forward progress, so I'm counting it today. I need all the fwd progress that I can get.

3. I found the perfect seals on Ebay for the inner fender/outer fender and I'll be ordering them tonight.

I may start throwing receipts away on this project. . . This sh*t is getting expensive and completely depressing . . I'm a freakin' privateer on a shoestring budget and and prayer!!!!!!!!!

[aircooledtechguy]

No pics today. . . Just verbage.

Had a couple days that disappointed me and ended up as wasted time, which I can't afford at this point with less than 50 days to go before World of Speed @ Bonneville. Anyway, progress was made on 2 fronts. . .

1. I got the inner fenders sealed for the NACA ducts to bring cooling air to the engine. This was huge. Originally, I had grandiose schemes of ducting from the NACA ducts to the inner fenders, however I had grossly over thought this. All I needed to do was to prevent air from traveling from the NACA ducts to the rear section of the fenders and attempted a fiberglass ducting system to make this happen. . . I lost a n entire day on this fiasco. A simple 6" wall prevents this and the "lazy air" will have no choice but to go down the duct over the rear tire and into the engine. Woohoo!! A HUGE burden has been lifted off my shoulders. . .

2. I now have brakes. Yeah, racing at Bonneville make brakes kind of the last thing you need to be concerned about, but it was forward progress, so I'm counting it today. I need all the fwd progress that I can get.

3. I found the perfect seals on Ebay for the inner fender/outer fender and I'll be ordering them tonight.

I may start throwing receipts away on this project. . . This sh*t is getting expensive and completely depressing . . I'm a freakin' privateer on a shoestring budget and and prayer!!!!!!!!!

[rhodyguy]

nate, how will you deal with the salt and the bottom of the engine? some sort of covering?

[aircooledtechguy]

nate, how will you deal with the salt and the bottom of the engine? some sort of covering?

I could install a belly pan to cover/fair the engine/trans, but there's no time for that this year anyway. I'll just have to pressure wash it after the meet since there's nothing else I can do about that while I'm there.

For next year, there are some serious changes coming to the Squarsche and front/rear belly pans may factor into those changes. If I build a spec car, I'm allowed to fair up to 50% of the bottom on a stock bodied car. Since VWs come with a flat belly pan from the factory, I only have 40-45% to do anyway to make a 100% faired belly.

[Dave_Darling]

Just be sure you have enough cooling if you build an under-tray. There should be low pressure under the engine to draw the cooling air down across the fins, but low pressure will draw in salt and air, so...

Hopefully the air from the intakes will create enough pressure differential that cooling will be fine, but you might want to check that before putting the belly pan under the engine.

--DD

[VaccaRabite]

Nate, you ever get that package from me?
Zach

[aircooledtechguy]

Nate, you ever get that package from me?
Zach

I did Zach; Thanks. No time yet to get them mounted and snap some photos. They are STUNNING!!!!!!!!!!

[aircooledtechguy]

Just be sure you have enough cooling if you build an under-tray. There should be low pressure under the engine to draw the cooling air down across the fins, but low pressure will draw in salt and air, so...

Hopefully the air from the intakes will create enough pressure differential that cooling will be fine, but you might want to check that before putting the belly pan under the engine.

--DD

A lot of thought will have to go into belly pans in the rear for sure. Access to low pressure is not a huge problem with this car due to that flat rear-end (IMG:style_emoticons/default/huh.gif) That vacuum at the rear is gonna be an issue with this car going fast fo'sho' (IMG:style_emoticons/default/driving.gif)

[aircooledtechguy]

After weeks of delays due to shop and family commitments as well as part incompatibility issues, Josh was finally able to finish the engine build that he started several weeks ago. None too soon I might add since it is getting down to the wire on this project!!

One of the issues we had was when I ordered a ring set, TWICE, I was sent the wrong oil control rings. Each time, causing a week or more in delays. . . Man was it nice to get those cylinders on and the motor finished. Here are a few shots of Josh back at it getting the cylinders prepped and heads on and torqued.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385066.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385067.2.jpg)
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After we determined our rocker geometry and made adjustments via shims and push rod length, Josh got down to making the custom length chromoly push rods. He did a fantastic job!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385069.6.jpg)
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He then was able to get the modified 1.7L rockers w/ OEM Porsche 911 adjusters installed and the valves adjusted.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385069.8.jpg)

We’re going to start the motor with these bolt-on covers. Yeah, yeah, I know; they will probably leak, but we gotta try ‘em anyway since they’re easy to change out for stockers. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385070.9.jpg)

Before the engine tins went on, we set the air gap at the hall sensor and 36-1 trigger wheel to 3mm and verified a good signal with a multimeter. We wanted to do this now since getting at it later will be “fun”.

Then began the job of the engine tins. We robbed these off the old 2056cc and cleaned them-up.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385071.10.jpg)

After that, we mounted the ITBs and synced the linkage, which only took about 30 seconds (try syncing any other type of linkage that fast).

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385071.11.jpg)

Then I had Josh break out the torch and anneal the copper exhaust gaskets so they would be butter-soft for good stub sealing.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385072.12.jpg)

After they cooled, he installed them into the ports, anti-seized the studs and mounted the custom stubs using OEM Porsche 914 2.0L exhaust nuts.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385072.13.jpg)
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Below is a shot of Josh and his first motor build. I’m really proud of him and what he has created here.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385073.15.jpg)

Today, I had to make an exhaust hanger just before the V-band. With the 911 muffler, this is not needed, but if I run a straight pipe, it will need to be supported. This is what I came up with.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385074.16.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385074.17.jpg)

Then we got the header on and the muffler installed.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407385074.18.jpg)
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[JRust]

Lookin good Nate! What a great build & Josh is into it. Well done man! Good to see a young man cutting his teeth air cooled style (IMG:style_emoticons/default/evilgrin.gif)

[Cap'n Krusty]

Nice. Looks like you've infected your son with the car bug ............... Please 'splain to him the benefits of using the box end of the wrench on those valve adjuster lock nuts. Tell him Cap'n Krusty says to do it.

The Cap'n

[aircooledtechguy]

Nice. Looks like you've infected your son with the car bug ............... Please 'splain to him the benefits of using the box end of the wrench on those valve adjuster lock nuts. Tell him Cap'n Krusty says to do it.

The Cap'n

(IMG:style_emoticons/default/lol-2.gif) Nice catch Krusty!! Will do sir, will do!! (IMG:style_emoticons/default/beerchug.gif)

[Cap'n Krusty]

See? I LOOK at the pictures, albeit mostly in envy. Way to go!

The Cap'n

[aircooledtechguy]

Thanks for the kind words guys. Even through all the smart-@$$ness, I think Josh is picking this stuff up pretty good and is doing a great job on his part.

I made some more progress yesterday. I modified the tank (via BAH (IMG:style_emoticons/default/laugh.gif) ) and got it mounted. That enabled me to be able to finalize the front strut bar and weld-in the studs for it.

(IMG:http://images.thesamba.com/vw/gallery/pix/1241954.jpg)

This is the first front stiffener to go in. I'm going to be doing some testing in the months to come to see if more will be needed.

I also made the spoiler stiffener support and mounted it to the inside of the spoiler. This is necessary because all the force of the air at high speeds will eventually break the mounts for the bumper since they are just fiberglassed in place. This will support the bottom really nicely and make it solid at high speeds. I still need to make the strut bars that tie it to the front suspension, Since I ran out of materials.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407690011.1.jpg)

I also mounted & plumbed the Walbro fuel pump and filter as well as ran all the front fuel hoses.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1407690012.2.jpg)

[jaxdream]

Shouldn't your fuel hose / lines be 30R9 instead of 7 ???? maybe I gots it bakards . Still a great looking Square !!!! (IMG:style_emoticons/default/piratenanner.gif)

Jack

[rhodyguy]

i dunno, the fuel line is clearly marked 'not for fuel injection'. i use the same line on my car but with carbs. the line on the pump outlet needs a shouldered clamp and it looks a bit 'stressed' where it goes over the fitting. what pressure does that pump run at?

[aircooledtechguy]

That fuel hose is a return hose so there is no pressure. All pressure hoses are EFI rated hose. Not to worry gents.

The pump is rated @ about 50psi unregulated and will be regulated down to about 40psi. Again, all hose that is in the pressure loop from the pump outlet to the regulator is the appropriate EFI rated hose. From the tank to the pump & from the regulator outlet to the tank does not require a special EFI type of hose because it's under no pressure.

[Cap'n Krusty]

Bad news? http://autoweek.com/article/car-news/2014-...gn=awdailydrive

The Cap'n