Do you need a new throttle body? |
Oh yes, please, mine's like a screen door after Katrina |
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63% |
[ 35 ] |
No, I like my crappy idle, surging and hot-starting problems just fine, thanks |
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12% |
[ 7 ] |
What's a throttle body? |
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23% |
[ 13 ] |
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Total Votes : 55 |
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tencentlife Samba Member
Joined: May 02, 2006 Posts: 10147 Location: Abiquiu, NM, USA
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Posted: Thu Apr 24, 2008 8:42 pm Post subject: Shiny new TB from scratch; pics |
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Here's a few shots of the project that has been busying me these last few weeks: a brand spankin new throttle body to replace the badly-designed worn-out POS that came on the wbx, and a complete workaround for the idiotic TB switches. This is the kind of fun you can have when you get a few small machine tools.
I love this stuff!
It's made up of a 1/2" adapter plate that fits to the tapered plenum spigot, using the OEM sealing ring.
Then the main valve body with butterfly and idle bypass circuit bolts to the face of the adapter. A tube extension seals with an o-ring into the valve body, and has a groove with another fat o-ring for the rubber intake bellows to grip and seal to.
You can see the idle air screw on the rear face of the valve body. I left the top surface clear because i didn't know if I would need to mount a switch there, but it's not going to be necessary, so future copies will have the air screw there where it will be easier to access.
Here's the adapter and valve body laid together, viewed from the engine side. You can see a slot between them, which is the delivery point for the idle air bypass. The inlet is a hole just upstream of the butterfly. The idle air screw varies how much air can flow around the butterfly thru this route.
I made the body as three pieces like this to save materials and make the process easier. Otherwise it would have to be made from a solid 4" round bar, with most of the material being turned into waste. The o-ring seal for the bellows is needed because the 2" aluminum pipe I can get is a little smaller OD than the OD of the stock TB spigot. It does make a good seal and grip, though. The adapter plate snugs down so the plenum spigot ends up butting right against the back of the valve body, eliminating a huge vacant groove left there in the stock installation, so it's a lot more aerodynamic internally once installed.
The 1/4" brass shaft runs in two tiny sealed stainless ball-bearings, and shaft endplay is tightly controlled, so there will be no wear on the ends of the butterfly, unlike the stock design that used the butterfly itself as an axial control, which guaranteed that it would wear badly.
I managed to get the clearance down to .001-.0015" all around the butterfly. That sounds pretty good, but I'd like to get it tighter still.
I drilled and countersunk the plate for flathead screws, so that side of the plate is smooth and aerodynamic, but the countersinks mean that the plate will center to the screws when tightened. That means the drillings have to be super-precise in the plate and the shaft, but it's tough to get the locations to within less than .001". Next time I'll just use some panhead screws because even though the heads will be bumps in the WOT airflow, it will enable me to locate the plate laterally with more precision after the fact. That will let me turn the butterfly to a total of .001" less than the bore diameter and still get it centered in the final install.
And finally, my secret weapon. I'm using an adjustable, very sensitive vacuum switch to replace the OEM mechanical TB switch or switches. I have it wired to the unused OXS LED in my inst. cluster as a test so I can see how it responds. The LED lights whenever there is switch closure, at idle and under load. This thing is far more responsive to transition off idle, the slightest touch of the pedal makes the LED go out, and it gives a WOT switch closure whenever manifold vac falls to less than 1"Hg. That means that the enrichment signal is given even at mid-throttle if engine load is high. No need to hold the pedal to the floor to get the ECU to run open-loop. Instead, it gives the signal when load is high, and opens again as vac returns, regardless of pedal position. Sometimes you're WOT, but don't need open-loop. This knows the difference. It just works on the EEC signal line.
Sorry, no pics of that.
Anyway, enjoy! And if anyone would like a copy, after working out any bugs I'll be offering these on my ad. Link below. _________________ Shop for unique and useful Vanagon accessories at the Vanistan shop:
https://intrepidoverland.com/vanistan/
also available at VanCafe.com!
Please don't PM here, I will not reply.
Experience is death to doctrine. |
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Christopher Schimke Samba Member

Joined: August 03, 2005 Posts: 5524 Location: PNW
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Posted: Thu Apr 24, 2008 8:48 pm Post subject: |
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HOLY CRAP!!!! I love you! _________________ "Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)
*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected] |
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funagon Samba Member

Joined: March 09, 2006 Posts: 1308 Location: SLC, UT
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Posted: Thu Apr 24, 2008 8:56 pm Post subject: |
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That is awesome tencent. So, is it installed in the van, and are you driving it?
I didn't answer your survey because my lo-mileage van has a good TB. But I will need one eventually, just like everyone else who wants to keep driving these vans for years to come. _________________ 1990 GL 7-passenger
2.2 liter WBX |
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Dogpilot Samba Member

Joined: October 03, 2005 Posts: 4205 Location: Flagstaff, AZ
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Posted: Thu Apr 24, 2008 8:58 pm Post subject: |
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Very nicely done! I think the vacuum switch is beyond clever, have you been raiding my Demerol supply? I have interest in one of your production models when you get it refined.
Bravo! _________________ Geology with a Syncro rocks!
86 Syncro Westy AKA "The Bughunter"
98 Disco I
08 Range Rover SC
08 VW Rabbit S
1951 O-1G |
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tencentlife Samba Member
Joined: May 02, 2006 Posts: 10147 Location: Abiquiu, NM, USA
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Posted: Thu Apr 24, 2008 9:13 pm Post subject: |
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Oh, I forgot the installed pic, didn't I?
Thanks guys, glad you like it.
Oh, and Dog? save some. _________________ Shop for unique and useful Vanagon accessories at the Vanistan shop:
https://intrepidoverland.com/vanistan/
also available at VanCafe.com!
Please don't PM here, I will not reply.
Experience is death to doctrine. |
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rogerw Samba Member
Joined: October 15, 2007 Posts: 40 Location: seattle, wa
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Posted: Thu Apr 24, 2008 9:51 pm Post subject: |
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I don't "need one" but that won't stop me from sending you a check. That TB looks sweet and would be one more reason not to more seriously plan for the suby swap. Thanks for adding to the list of parts I need to buy from 10C (exhuast, TB, motor).
Again, nice work. _________________ RW
____________________________________
87 Sunroof Syncro with full Bluestar interior |
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CF Samba Member
Joined: February 17, 2005 Posts: 802
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Posted: Fri Apr 25, 2008 1:12 am Post subject: |
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some one has a bit of time on their hands...............lol
nice job....... |
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sagebus Samba Member

Joined: July 26, 2004 Posts: 310 Location: Temescal Valley, Corona California
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Posted: Fri Apr 25, 2008 6:55 am Post subject: |
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The wish list keeps growing. I dream about that fine engine you build, Have lusted over the SS exhaust, And today I marvel over that throttle body! Wow ! Fine work! Keep it up. _________________ 1984 Vanagon GL, Wolfsburg Westy 1.9 ltr |
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snoop Samba Member

Joined: June 22, 2007 Posts: 371 Location: SW Oregon
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Posted: Fri Apr 25, 2008 7:08 am Post subject: |
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Schweet! The camel's gonna need a "10¢ powered" bumper sticker . _________________ 87 Westy Camper |
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Wellington Samba Member
Joined: September 21, 2004 Posts: 1994 Location: Montreal
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Posted: Fri Apr 25, 2008 9:08 am Post subject: |
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I'm loving it! |
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inspector58 Samba Member

Joined: March 11, 2008 Posts: 53 Location: Amarillo, Texas
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Posted: Fri Apr 25, 2008 9:27 am Post subject: |
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Very nice work!! _________________ Loud pipes save lives! |
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allsierra123 Samba Member
Joined: August 19, 2006 Posts: 1462 Location: Tecate, Baja California MX
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Posted: Fri Apr 25, 2008 10:40 am Post subject: |
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Dang 10c you are going to make start wanting to build up a very high performance 2.1 If you could do something for the leaky head problem then I would be all over keeping my engine. _________________ 95 GMC Yukon 6.5 TD 2 Door Tow pig/ Daily driver.
91 Vanagon GL. 1.9TD Conversion Sold
81 Vw rabbit 1.6 Diesel. Sold |
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tencentlife Samba Member
Joined: May 02, 2006 Posts: 10147 Location: Abiquiu, NM, USA
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Posted: Fri Apr 25, 2008 10:48 am Post subject: |
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No 2.1's coming outa my shop.
2.2 and up.
There's a leaky head problem? _________________ Shop for unique and useful Vanagon accessories at the Vanistan shop:
https://intrepidoverland.com/vanistan/
also available at VanCafe.com!
Please don't PM here, I will not reply.
Experience is death to doctrine. |
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Vanagon Nut Samba Member

Joined: February 08, 2008 Posts: 10494 Location: Sunshine Coast B.C.
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Posted: Fri Apr 25, 2008 11:00 am Post subject: |
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Mr. .10
What *little* I've done turning stuff, or "designing" anything (adapting actually..... and limited to "L" bracket complexity at that ) sure makes me appreciate the work you've done.
Bravo!
Neil. _________________ 1981 Westy DIY 15º ABA
(VW Gas I4)
1988 Westy DIY 50º ABA
VE7TBN |
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allsierra123 Samba Member
Joined: August 19, 2006 Posts: 1462 Location: Tecate, Baja California MX
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Posted: Fri Apr 25, 2008 11:02 am Post subject: |
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yeah I need to see what I can do to remedy it before I put my engine back in my van. _________________ 95 GMC Yukon 6.5 TD 2 Door Tow pig/ Daily driver.
91 Vanagon GL. 1.9TD Conversion Sold
81 Vw rabbit 1.6 Diesel. Sold |
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floggingmolly Samba Member

Joined: April 06, 2007 Posts: 1106 Location: San Diego, CA
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Posted: Fri Apr 25, 2008 3:28 pm Post subject: |
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Awesome. And I thought home remodeling was a challenge. Geez. _________________ '85 Wolfsburg Weekender |
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brooklynvan Samba Member

Joined: February 08, 2006 Posts: 342 Location: Brooklyn NY
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Posted: Fri Apr 25, 2008 3:42 pm Post subject: |
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in awe.
Can you put one on the engine I hope to get from you? _________________ 1990 Vanagon "Plain Jane" Bostig in the Back
TRADED: 1967 Panel for 1976 BMW 2002
SOLD: 1984 Sunroof Vanagon with EJ22
RIP 1986 Saab turbo
and my daily commuter: a Bicycle |
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Crankey Samba Member

Joined: July 11, 2004 Posts: 2672
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Posted: Fri Apr 25, 2008 4:56 pm Post subject: |
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wow, killer ! I want one now ! with you, I may not do that subaru conversion. I still love that SVX manifold
but seriously I really find your work really interesting. I planned on a subie at some point but I might not since your work on the WBX is making it more interesting.
I'm definatly interested in the SS exhaust. |
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snoop Samba Member

Joined: June 22, 2007 Posts: 371 Location: SW Oregon
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Posted: Fri Apr 25, 2008 8:20 pm Post subject: |
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Presumably no compatibility issue with the GW hot wire AFM...right? Or non-stock 2.1s (in particular GW WBXers)? Is tuning of your TB required (read: possible) for these motors? And/or when vented by your TBA headers? And/or to optimize 1.25 ratio rockers? With apologies for my ignorance, the more sophisticated the reply, the better.
Most sincere thanks for your efforts to keep vanagons volkswagens. _________________ 87 Westy Camper |
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allsierra123 Samba Member
Joined: August 19, 2006 Posts: 1462 Location: Tecate, Baja California MX
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Posted: Fri Apr 25, 2008 9:23 pm Post subject: |
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Is this going to mean better gas mileage? _________________ 95 GMC Yukon 6.5 TD 2 Door Tow pig/ Daily driver.
91 Vanagon GL. 1.9TD Conversion Sold
81 Vw rabbit 1.6 Diesel. Sold |
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