The Ultimate Daily Driver: UPDATE

[scott s]

It all started over three years ago with a sale at now-defunct Serrano's. I picked up a CB Perf. crank, rods and P/C's at a smoking deal and stuck them in my closet. I didn't even have a car to put them in at the time. (Please, let's not start a "Serrano's" thread out of this.)
I had sold my daily driver '66 to my Dad after I got divorced. I had driven the 1,955cc with IDA's and Street Eliminators daily for 3.5 years, but now that there were NO other cars in the family except for my '63 ragtop, I decided I needed a "real" car to get around in. So Dad got the '66 and I bought a Mitsubishi.
Shortly after that I was working on my chop-top project and realized just how much I missed driving a Bug daily. I started thinking: "What would I build if I started all over again?".
I decided on a late model Bug this time for several reasons; they're generally less expensive and easier to find, they're easier to set up for handling, and brakes are easier to upgrade and less expensive than wide-5 cars.
I was thinking of a cross between traditional Cal-Look, resto-custom and a German Looker.
It didn't take long for me to stumble across a 1970 on ebay. It was a few hundred miles away in Knoxville, TN. I put in what I thought was a low-ball bid and WON! We flew in to Knoxville to inspect the car.
It turns out that the car had belonged to an 87 year old man who purchased it new. The ebay'er had done an exterior repaint and added new rubber and seals and a set of 8 spokes, but everything else was original, straight from Germany. The title was still in the original owners name, so legally I'm the second owner. I happily paid the winning bid amount and we drove "Fred" back home over the Great Smoky Mountains, not missing a beat.
Here's what it looked like when I brought it home:

[scott s]

While I continued to collect parts and gather data about the engine, I made some minor changes to the car. Most of it was very minor and all are reversible. Stuff like adding a stereo, my Berg shifter, a tach, some interia reel seat belts from a later model, etc.
While the interior was all original, the carpet and rubber floor mats had seen better days. They were basically dry rotted and turning to dust under my feet. I replaced them with the same, original style with stuff from Sewfine.
The most noticible difference was to the suspension. I purchased a set of discs/drums from fellow CLF'er Victor H and installed a set of polished 2.0L Fuchs. I added KYB GR2 shocks (front from an Opel GT...thanks Glenn, for the suggestion!), S.A.W. sway bars front and rear, and new tires...175/55 and 205/60. Upgraded pads, front and rear, too.
The car handles great, rides almost as smooth as stock and stops on a dime.

[scott s]

After about three years of collecting engine parts, I had everything I needed to build the motor. I decided on a 2,110cc for the best cooling and longevity. I also wanted heat, so 1.5" heaterboxes from Kymco were part of the equation. After tallking to several head porters about running the 1.5" exhaust, I liked what Darren at DRD had to say the best. He built me a set of L5's with 40x35.5 valves, set up for low and mid-range power. He also recommended the SLR XR-302 cam. I took Glenns advice and ran a Bosch 010 with Pertronix module and MSD 6AL. I had a set of 45 Dell's tucked away that would be perfect for this project.
Here are a few pics of the parts and a "build sheet":

82mm CB crank
5.400" H-beams
90.5 P/C's
SLR XR-302 cam, 106* lobe centers
Bugpack straight cuts
Udos lifters, Manton pushrods
DRD L5 heads, 40x35.5, matched manifolds
3.5 qt. sump, Berg full-flow system
45 Dell's w/ CB update kit
Bosch 010, rebuilt by me
Pertronix Ignitor, Taylor wires and MSD 6AL
12.5lb flywheel, 1700 KEP, Copperhead disc
9.24:1 CR
Balanced, built and dyno-tuned by KSR

[scott s]

I ran all German tin, even the little hard to find bits and pieces. Hoover bit, working thermostat, F.I. venturi ring, etc. It's all powdercoated satin black...very close to the original tin color.
The engine made 145 HP and 140TQ. Not bad for small valves and exhaust. The best thing is, it has GOBS of power down low. It's making 60HP and well over 100TQ at only 2500rpm. By 3500, it's at 138TQ and flattens out around 140 all the way to 5252rpm, when the HP picks up.
After repeated dyno flogging and a 90 mile drive home at highway speeds, the temps on all four heads are 250 degrees

[scott s]

Here's a before and after of the engine bay:

[scott s]

For the trans., I used a late model IRS with the "zig-zag" case. It's one of the strongest cases VW ever produced for the Type1, has many internal upgrades, a HD side cover comes stock, etc.
I had Kevin at KSR swap out the 3.88 R&P for a 4.12, since the '70 isn't exactly a lite car, upgraded to a 3.78/2.06 mainshaft, coarse tooth Bus gears for 3rd and 4th, 10/15 tooth Super Diff., heavy duty VW motor mounts and a Berg intermediate mount up front.
Basically, an extra strong version of the stock gearbox for a '70.
This is the tranny before being stripped down and rebuilt.

[scott s]

Everything is in the car now and I have about 200 miles on it so far. I have some very minor adjustments to make. I need to work on the CSP linkage, fix a short to the right rear tail light ( I think we might have knocked a wire loose when we installed the Weber Windows), and I have a very, very minor drip off the sump. I'll probably let that go 'til the first oil change. I also just want to do a little more detailing....straightening up wires, etc.
The car has tons of power all across the rev range. It's very smooth, like a smaller motor, but pulls hard in a linear fashion like a motor with more displacement. I can't wait to break it in and start driving it everyday!
Some more pics.

[scott s]

I'd also like to give big props to Kevin Shull at KSR. He not only notched the rain tray so I could run the decklid closed, he also made these trick connectors to go from the heaterboxes to the flex hoses.
Kevin builds a great engine and trans. and is an excellent fabricator.
The heat connectors have been painted with high-temp paint. The rain tray will come out soon for a fresh coat of paint and some underhood detailing

[Rowroy]

Look very good. I really like those wheels.
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[Fattie]

VERY NICE

keep the updates and pictures comming


your doing good bro
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[mattie]

Very cool ride! good job to you and Kevin at KSR.

[cobiray]

Wow, that looks great. Although, I do hate it when someone's "dirty" engine compartment is cleaner than my "clean" engine compartment.
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73 std (roller)
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[mla]

Very cool.

[oibovveroi]

very nice!
gave me a couple ideas.

[scott s]

Thanks Guys. I love it. Just a little more fiddling and break in time and the old Mazda pickup with 247,000 miles is outta here and I'll be driving a VW daily again!

[Rome]

Very interesting and attractive project! Thanks for sharing with us and listing your car's details. What fuel economy are you getting on highway driving (and at what speeds is that??), nowadays a very significant factor in a DD? Did you install a set of strong horns and a third brakelight for DD duties? Inertia reel belts are vital for that but you did that right away.

[scott s]

Haven't driven it enough to check mileage yet. It will handle highway speeds of 70+ with no problem and plenty of power to pass.
The stock horn is surprisingly loud. I'll probably skip the third brake light, though...

[zeenithman]

What size tires are you using?

[scott s]

Tires are 175/55 and 205/65. So far, I'm getting 23-24 MPG in mostly city driving. Almost no highway on my commute, etc., and that's "spirited" driving!
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Nothing screams "poor workmanship" like wrinkles in the duct tape.

[Derminger]

I am finding your info and ideas helpful.
nice car too

am currently building a low rpm, high torque 2110 for my wifes straight axle 3.88 1961 bus.

I ordered L3 heads from Darren at DRD and took his advice on cams as well. he talked about the issue with mismatched hardness on cams/lifters causing failure. he is grinding his version of a w100 / lifters for me.

the rest of the motor will be:
82x90.5, I-beams, supercase, single 44 HPMX, exhaust header. all else stock

should be great for her to drive around town, and awesome on the long trips to shows.