The Doc's tranny waggin' Options

[partwerks]

A friend of mine has something that I thought he said they only made like 11 of them. I think he called it a DK10??

 DK10.rtf ( 431.4k ) Number of downloads: 193

[Dr Evil]

One side of the engine is done today. The aluminum is ugly, but I had to do a lot of building up to do, and subsequent grinding. Eventually, I had to leave some globs on as the material was too thin. New injectors and hardware are installed (IMG:style_emoticons/default/smile.gif)

[Dr Evil]

Here is a link to the agonizing design of the CIS system (IMG:style_emoticons/default/smile.gif)
http://www.914world.com/bbs2/index.php?showtopic=167036

[Dr Evil]

So, one of the design things needing to be addressed to meet the and of the month deadline for completion is how to hook the CIS box to the intake. I have been looking at Volvo air boots, but the best think I am seeing is the 924 boot here:
http://www.ebay.com/itm/Brand-New-Porsche-...de7&vxp=mtr

Any other suggestions? I am wishing to go from vertical to horizontal and with the 924 boot I can do this with a simple elbow (IMG:style_emoticons/default/smile.gif)

[jsayre914]

I hope you bring this to Hershey Mike, cant wait to check it out

(IMG:style_emoticons/default/driving.gif)









p.s. I will try not to cut you off this year (IMG:style_emoticons/default/rolleyes.gif)

[Jeffs9146]

So, one of the design things needing to be addressed to meet the and of the month deadline for completion is how to hook the CIS box to the intake. I have been looking at Volvo air boots, but the best think I am seeing is the 924 boot here:
http://www.ebay.com/itm/Brand-New-Porsche-...de7&vxp=mtr

Any other suggestions? I am wishing to go from vertical to horizontal and with the 924 boot I can do this with a simple elbow (IMG:style_emoticons/default/smile.gif)

That looks very similar to the 3.0L intake!

You can do something like I did for the Volvo intake and the welded up elbow. I cut the original intake boot and made the elbow to fit my needs! Then I clamped the cut intake to the elbow to match everything together!

[Dr Evil]

The problem I see in cutting the OE boot is that it is oval. The 924 boot is circular so plumbing the rest would be easier with standard plumbing supplies (IMG:style_emoticons/default/confused24.gif)

At present, I am waiting to get the pipes for the down tubes, they ship on the 19th and this has held everything up. Once the plenum is built, i can install the engine, decide location of the airbox, measure FI hose lengths and order them, and make new engine tin while I wait. I can still make the end of the month deadline, but having to order out all of these damn parts is killing my timeline.

[Dr Evil]

Back to posting in this thread. I have the heads done up and installed, the adapters welded up and installed withe new injectors and hardware, welded on the mounts for the AAR and the WUR. I diagrammed out the vacuum, fuel and electrical schematics that I will use to guide assembly and found that I am in need of 3 electrical plugs for the AAR, WUR, and CSI. I also found that I need a thermotime switch for the CSI....I think a 914 one should work so any used ones out there? (IMG:style_emoticons/default/biggrin.gif) You can also appreciate the billet pulleys I got to keep the belt form getting scruffed on rusty steel pulleys. Still need to keep the man crank pulley rust free and the alternator one, too.

[Dr Evil]

Some more victory last night with the making of the base plates for the intake system (IMG:style_emoticons/default/smile.gif) I first made my own gaskets, then I transferred the pattern onto the 1/4" 6061 Al plate and drilled out the holes. It all lines up! The down tubes are reported to ship tomorrow and I cant wait for them to get here so I can get this all buttoned up and installed for testing.


I also took a different route with the air box for the flapper and dist. I had been generously given a nice aluminum setup out of a Volvo, but the filter that would have to be used would be of the cone-style KN that would be pretty small. So, I came across a setup for a VW rabbit (I think) that uses readily available disposable filters. I also found a refresh kit with new copper washers and a gasket for the flapper assembly. Good price and looks appropriate for what I need.

[jmill]

Wonder what the wagon would look like with a 914 painted on the side. (IMG:style_emoticons/default/idea.gif)

[Dr Evil]

The down tube stock showed up today and I got to work quickly after I got home....from work (IMG:style_emoticons/default/rolleyes.gif)

Welding aluminum is difficult. I have yet to need to weld a straight line (IMG:style_emoticons/default/dry.gif) I think I finally got it dialed in. I also think that gun was not feeding uniformly so I fixed it (IMG:style_emoticons/default/smile.gif)

[Dr Evil]

These are the last welds when I got the feed and the power correct. You have to weld fast!

[rick 918-S]

Hey Mike, Get a stainless wire brush and clean all the pipe surfaces where your welding. Use a new clean brush that you only use for aluminum.

Edit: On second look I think I can see where you cleaned the 90's

[Dr Evil]

Yup, I have a brush just for this that is stainless. I cant imagine how crappy the welds would be if it didnt (IMG:style_emoticons/default/blink.gif)

The first set was a PITA as it would randomly burn through. I think I was welding too much at a time. The metal would flow through the burn through and make nice, HUGE boogers that I had to dremel out (IMG:style_emoticons/default/dry.gif) If I could weld better, I would be done (IMG:style_emoticons/default/biggrin.gif)

[brer]

good work mike! took me awhile to get the hang of it.
when you can weld a beer can back together you're getting good.

[Dr Evil]

I started on the hard stuff with the smaller tubes. I just finished up the large tubes and my welds were going awesome! Then I ran out of wire (IMG:style_emoticons/default/dry.gif) I put my other role of 4043 in and it kept misfeeding.....it was .030 and the feed wheel was .035. Off to the store to get a new spool and all they had was 54XX or something. Welded very different. Nothing a sanding disk couldnt fix (IMG:style_emoticons/default/thumb3d.gif)

I am taking a break for the moment to post pics (IMG:style_emoticons/default/smile.gif)

[Dr Evil]

Alright, I am calling it a night. I am out of sanding disks anyway. I got one side almost completely done. I had to re-weld the one side as I noticed cracks when I hit it with the hammer (good test). Added material and ground it down again. All that is left on this piece is to throw a bunch of nuts in it and shake it around to break loose any metal boogers that might have formed with welding.

[zymurgist]

(IMG:style_emoticons/default/thumb3d.gif)

[Dr Evil]

PROOF that I can weld in a straight line (IMG:style_emoticons/default/wink.gif)


Second side


Both done (IMG:style_emoticons/default/smile.gif)

[Dr Evil]

So, rattled some nuts around in them and got only a few little nuggets of slag. Then I leak tested them.......and went to repair some welds (IMG:style_emoticons/default/rolleyes.gif)

Now to leak test the other one (yay).