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> Sasquatch Part III Audi 1.8t transplant..., PCV upgrades finally...
FourBlades
post Dec 27 2012, 10:29 PM
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(IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif)

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John
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Mike Bellis
post Dec 31 2012, 11:43 PM
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Got most of the rear area and ECU wired. I'm down to 6 or 7 wires but rand out of connectors. I can't believe how many wires I have connected.... (IMG:style_emoticons/default/blink.gif)

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Andyrew
post Jan 1 2013, 02:01 PM
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I like the progress!!
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Mike Bellis
post Jan 19 2013, 07:54 PM
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Progress continues even without updates. The wiring has taken longer since I'm adding connectors and soldering connections...

Got the cluster figured out. i was going to build a custom fiberglass dash but decided to go another route.

I first broke off the factory clear lens on the cluster and cut the black surround down. I had a piece of acrylic cut to the outer shape of the 914 cluster. The Passat dash is slightly narrower but slightly taller. I used an epoxy designed to bond the ABS to the acrylic. I then painted the acrylic satin black around the edge...

I think it looks pretty good and I get to keep the stock 914 dash shape... (IMG:style_emoticons/default/smile.gif)

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JRust
post Jan 19 2013, 08:50 PM
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Yeah Buddy (IMG:style_emoticons/default/piratenanner.gif) Lookin sweet! Going to be a trip seeing that all going in your 914. A nice updated cluster & steering wheel controls. Good to see you making progress. Can't wait to see it at WCR
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Andyrew
post Jan 21 2013, 02:12 AM
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Like the gauge cluster idea (IMG:style_emoticons/default/smile.gif)
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Mike Bellis
post Feb 3 2013, 07:48 PM
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I'm getting burned out on wiring... (IMG:style_emoticons/default/dry.gif)

Today I switched to steering. I had to shorted the under dash steering rod by 2.5 inches. So I cut it in half, connected everything and marked it. I then cut off the excess. I don;t want this weld to fail so I did it more like a structural weld. Note the chamfers on each section. I used an angle aluminum piece in the vice and over clamped it so the heat would not pull the rod. It was welded, ground and spun... Over and over. It is not warped or bent at all. A quick coat of satin black finished it off.

I did discover the VW clock spring does 7 complete revolutions. I never looked to see what the 914 does lock to lock but I hope 7 is OK.

Kind of a boring update but if it don't steer, it don't drive...

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Andyrew
post Feb 4 2013, 12:36 AM
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Looks great! Even if it was warped a hair, its just a steering rack...

Progress good!
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Chris H.
post Feb 4 2013, 07:41 AM
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Mike...your gauge cluster....awesome man! The gauges look factory that way!
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jeeperjohn56
post Feb 4 2013, 06:01 PM
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Hey Mike, Your doing a great job keep up the great work. John (IMG:style_emoticons/default/welder.gif)
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Mike Bellis
post Mar 10 2013, 07:47 PM
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Well, my car has had 930 steel flares. The right rear was hammered and rolled with a baseball bat at some point. The worse part was the execution. Since the car was once a race car, the PO or PPO did not car how it got installed. They just needed to cover the tires.

They don't look too bad from the outside...

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Here you can see 3 layers of sheet metal. (IMG:style_emoticons/default/barf.gif)

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Here you can see 1/2" of bondo. (IMG:style_emoticons/default/dry.gif) White painted fender makes it look thicker.

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I picked up a full set from AIR and 914 LTD. I also picked up some black fender welting. right now I just have them screwed on. I have wide rivets for later down the road. I was bidding on Brad's set (including rockers), lost the bid, bought a set from AIR and then Brad sent me a second chance offer. Now I have 2 complete sets. I already had flared steel rockers but realized the length of each was not consistent. Looks like the PO installed the old flares and built the rockers to fit. All of the old flares were off set different from the opposite side; Asymmetrical. (IMG:style_emoticons/default/WTF.gif) The worst was the front right which was set back a full inch from the left. (IMG:style_emoticons/default/drunk.gif)

So... I installed the new rockers first and installed the flares to meet. The jack post hole was the original alignment point. The ones I chose to install are from 914 LTD. The quality of both were good. The fit was almost the same. The 914 LTD flares were slightly thicker than the AIR's. I did notice that the gel coating on Brad's is cracking. I will deal with this someday when I paint the car.

If anyone needs a set of 4 fiberglass flares PM me. I will sell them for cost. I also have some free steel flared rockers if anyone wants them.

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Andyrew
post Mar 12 2013, 06:07 PM
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Looks great! Crazy work on those original flares!
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76-914
post Mar 12 2013, 07:12 PM
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That was a good idea on the dash set up, Mike.
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Mike Bellis
post Mar 12 2013, 07:30 PM
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QUOTE(76-914 @ Mar 12 2013, 06:12 PM) *

That was a good idea on the dash set up, Mike.

Thanks,

I actually went this route because it looked easier than any other custom work. I think it turned out better than expected. The pics in the thread show it not even in final position. I just placed it there for pics. The final position looks almost factory installed. Well, if you had a 2001 914, that is...
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3d914
post Mar 12 2013, 07:32 PM
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QUOTE(kg6dxn @ Mar 10 2013, 06:47 PM) *

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Mike, I like your approach to the gauge panel. I was thinking something similar if I decide to use the SHO gauge panel, but using stock steering column.

I'm curious about the NACA duct on the side. Is that something you added or PO? I'm looking for just that size to mount for intake air, but on the trunk.
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Mike Bellis
post Mar 12 2013, 07:33 PM
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QUOTE(Andyrew @ Mar 12 2013, 05:07 PM) *

Looks great! Crazy work on those original flares!

They look worse in person. There is 10lbs of bondo on each fender. I also found a bondo dent repair on the front right side. I cut most of it out but it will require some welding at some point. That will be in Part 4 of the build when I strip it for paint.

I think I dropped 50lbs off the car with the fiberglass flares and rockers... (IMG:style_emoticons/default/smile.gif)
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Mike Bellis
post Mar 12 2013, 07:39 PM
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QUOTE(3d914 @ Mar 12 2013, 06:32 PM) *

Mike, I like your approach to the gauge panel. I was thinking something similar if I decide to use the SHO gauge panel, but using stock steering column.

I'm curious about the NACA duct on the side. Is that something you added or PO? I'm looking for just that size to mount for intake air, but on the trunk.

The NACA was an ebay purchase. This one is setup as a cold air intake for the turbo. It was plumbed into a plenum but now the inner fender is the plenum. On the other side of the car, the NACA is the intake for the intercooler's heat exchanger. I cut it down to match the contour of the exchanger...

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Andyrew
post Mar 13 2013, 10:29 AM
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That should help some (IMG:style_emoticons/default/smile.gif) Not sure if thats really enough flow over the intercooler though. Something youll find out when you log your Intake Air Temps after you get the setup up and running.

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Mike Bellis
post Mar 13 2013, 12:01 PM
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QUOTE(Andyrew @ Mar 13 2013, 09:29 AM) *

That should help some (IMG:style_emoticons/default/smile.gif) Not sure if thats really enough flow over the intercooler though. Something youll find out when you log your Intake Air Temps after you get the setup up and running.

I have a 7" fan behind there too. I measured the IAT sensor at 120F after some hard driving with the old motor. I reconfigured the IC mounting to eliminate air bubbles within so I hope to have even cooler are now.
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Andyrew
post Mar 13 2013, 02:12 PM
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Is that the air to air intercooler or is it for the air to water intercooler?
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