Brian's V-6 rail (re)build (pics added daily)

bigrich424 · Posted: Thu May 27, 2010 5:39 pm Post subject:

Wow this is an inspiration..... Looks Great man can't wait to see it in action!!!!

quadrazer · Posted: Thu May 27, 2010 6:01 pm Post subject:

quadrazer · Posted: Sat May 29, 2010 6:24 pm Post subject: Finally back on the rail!!!

Haven't touched the rail in 7 days due to all kinds of issues with my truck. Still have a few more things to take care of (on the truck), but nothing too pressing, so back on the rail I go!!!! Applause

So I eased back into the rail by finishing my Max-Air shock install. Bolted up the passenger side shock:
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

And then ran the air lines and mounted the filler port and aired them up to 70 psi with no leaks:
Image may have been reduced in size. Click image to view fullscreen.

I have a few hours tomorrow to see what I can get done, then it's BBQ time with family and friends!!! Hope everyone has a great holiday weekend! Allow me to snap a salute to my fellow veterans!!
_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Sun May 30, 2010 12:37 pm Post subject: Axles

My axles finally arrived yesterday. I got 19 1/4" long axles and new Type 2 CV's for my setup. I got them clocked, assembled and greased. I'll put them in tomorrow. Gotta get outside and enjoy this weather with the family and friends! Very Happy

Assembled and ready to install:
Image may have been reduced in size. Click image to view fullscreen.

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Mon May 31, 2010 5:36 pm Post subject: Axles installed

Got the axles installed today. Would have loved to done more, but we had a heck of a storm roll through (AGAIN Sad

) and knocked out power for a while, then I cleaned up the mess from last night's bonfire. Oh well....tomorrow is another day!!! Very Happy

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Wed Jun 02, 2010 5:13 pm Post subject: Oil pan and pickup

I thought I would share a few pics of the oil pan and oil pickup/screen assembly off of my Buick 3.8L V6 engine, as well as share a few tips about the modifications they have.

First off, the oil pan. It was modified by the previous owner of the engine when he ran it in his project vehicle. He cut the sump out of the pan, cut the flat section from another pan, and rewelded it (poorly, but not leaking) so the bottom was basically flat. The origional oil pan mounting flange was never modified, allowing use of the stock gasket. Look closely and you will see 2 drain plugs, one on the side and one on the bottom.
Overall, these modifications were a good thing for me, since this engine is running facing backwards (opposite it's normal position) in my rail. He had also tacked in 2 baffles inside the oil pan to keep the oil in the bottom of the pan, instead of sloshing up into the crank. These two pictures were before I cleaned and painted the pan:
Image may have been reduced in size. Click image to view fullscreen.

In this next picture, you will see the modified oil pickup screen that was in the engine (on the right) and the new, unmodified one I bought (on the left). The biggest modifications needed are to clock the new assembly so it bolts up AND drops into the correct location in the oil pan:
Image may have been reduced in size. Click image to view fullscreen.

You may be wondering why I didn't just reuse the origional pickup screen since it was already modified for this setup. The answer is in this picture:
Image may have been reduced in size. Click image to view fullscreen.

That little yellow flapper is the oil bypass flap for the screen, and it's spring loaded. It is only suppose to open in the event of a clogged screen so the engine still gets oil. As you can see in the above picture, it's hung open, which would allow unscreened oil into the system. Aside from that, the pickup tube was bent by hand and nearly kinked, plus it was a smaller overall tube diameter than my new unit.

Here is a picture of my new screen on the end of the pickup:
Image may have been reduced in size. Click image to view fullscreen.

And here is a picture of the new pickup screen after the initial clocking to align the mounting flange (old one used for reference):
Image may have been reduced in size. Click image to view fullscreen.

And the finished modifications of the new pickup next to the old one, the difference in tube size is very clear in this pic:
Image may have been reduced in size. Click image to view fullscreen.

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

ts39136 · Posted: Wed Jun 02, 2010 6:10 pm Post subject:

That's what I like to see... Good 'ol backwoods engineering.

Question... You said:

quadrazer · Posted: Wed Jun 02, 2010 6:32 pm Post subject:

Tim,

The benefit is that inertia will force the oil in the pan to the rear of the vehicle (in this case the front, or water pump side, of my engine). So having a pickup screen assembly which draws oil from the front of the engine oil pan (where the oil will be under acceleration and cruising) is a must.

In addition, having a flat bottom oil pan with no sump (where there would have been a sump at the rear of the engine) helps to keep the oil from pooling in any one area. With a lot of domestic engines, the oil pan sump would be in the rear, because the oil would normally pool there under acceleration. Since the engine is mounted backwards in my rail, a stock rear sump oil pan would have the opposite effect under acceleration, in that the oil would run up out of the sump towards the front of the oil pan....leaving no oil in the sump to pick up. Then......boom!! Shocked

In addition, even if you already have a fairly flat oil pan, if the pickup screen is on the rear of the engine (meaning towards the front of the vehicle),, and you mount that engine in a rail or Baja, then under acceleration the oil is moving AWAY from the pickup, which will oil starve the engine. The pickup HAS to be in a position at the rear of the vehicle to pick up oil under acceleration. And if you do decide to move the pickup, take note of how close it sits to the bottom of the oil pan in the stock location, so you can make it sit that close to the pan after you modify it.

I know that was long winded #Sleep

, but I hope it was clear! Very Happy

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

ts39136 · Posted: Wed Jun 02, 2010 6:43 pm Post subject:

That was great... Thanks for being long winded. Rolling Eyes

Makes sense.
_________________
My Build Page

manxbuggyman · Posted: Fri Jun 04, 2010 6:26 am Post subject:

Dude, I got to tell you, its guys like you that make me sick. It seems you have a clear plan of what and where you want this build to go. To make me even more upset is that you continue to work on it. Wink

Hell I can't make the time to put on all the new parts I have in my shop. Total insperation!!! Not sure it will help me to work on mine, but it is nice to watch yours. Keep up the good work.

quadrazer · Posted: Fri Jun 04, 2010 12:11 pm Post subject:

quadrazer · Posted: Fri Jun 04, 2010 7:28 pm Post subject:

Pulled the carburator off (for the last time) to install a new o-ring on the vacuum advance, and set it up. I'll install it on the intake tomorrow, along with the throttle cable end mount and fuel line.
Image may have been reduced in size. Click image to view fullscreen.

Hopefully I'll get my throttle cable tube, and the cable installed on Sunday. Tomorrow is going to be crazy busy with my daughter having a double header softball game, and then attending a birthday party, and then a graduation party. Shocked

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

ts39136 · Posted: Sat Jun 05, 2010 5:44 am Post subject:

That picture just makes me want to reach out and scratch it! Speak to the hand

I'll bet the trees will bend over to get a lick at it.

Very nice, Very nice indeed.
_________________
My Build Page

quadrazer · Posted: Sat Jun 05, 2010 6:02 am Post subject:

LOL! Thanks Tim!
_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Sun Jun 06, 2010 4:55 pm Post subject:

Although I have a few loose ends to tie up on my rail before I begin wiring it next week, I thought I would post a few pics of the brake lights and reverse lights I plan to use.

First up, the rear brake/turn/running lights. Very bright, and the right size to clean up the rear end in a tasteful way. These are bullet style chrome housings to kinda match the chrome round front turn signals and headlights I will run:
Image may have been reduced in size. Click image to view fullscreen.

Then, my reverse lights. Made by Hella, they are a flat mount style, with a brushed aluminum housing. When mounted, they are very low profile. I plan to use a narrow, 1/8" thin piece of aluminum sheet on the rear to mount these into, as well as the rear license plate light/holder. The upper one in this pic is how they look from the rear, while the lower one shows its thickness when mounted:
Image may have been reduced in size. Click image to view fullscreen.

These are the reverse light housings and bulbs. These housings will mount through the aluminum sheet:
Image may have been reduced in size. Click image to view fullscreen.

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Tue Jun 08, 2010 6:06 pm Post subject: Throttle tube/cable

I installed my throttle cable tube and cable tonight. It's the black tube that kind of piggy backs the clutch cable tube in the pics below. It's actually 1/2" tubing, and the reason for being so large is I want to eventually get a custom made push-pull style throttle cable, and when I do I will use this tube to mount it in to protect it. I used dry graphite to lube the inside of the tube for the current cable setup:
Image may have been reduced in size. Click image to view fullscreen.

The tube is bent up at an angle to meet the tail of the transmission, where it is rubber clamp mounted to the upper tailshaft bolt:
Image may have been reduced in size. Click image to view fullscreen.

And comes into the mount on the 650 Holley carb (no, the fuel line isn't hooked up yet Sad

):

I intend to change my return spring setup, as I feel it's too short, and not strong enough for my liking. In order to do so, I will have to make a mount to bolt to the intake riser (where the gold bolt is on the end of the spring). This mount will move the spring end mount towards the rear of the vehicle about an inch and a half. Then I'll install a dual (inner/outer) return spring setup.

I am now back to working hard on getting this done quickly, for a few reasons....

1. My kids are visiting their Grandparents out of state for a two weeks, so they are done with sports for a while (boy...the house is quiet! Confused

).

2. My truck is back up and running, so no distractions there. Pray

3. My wife is ready to have me start working on remodeling a few rooms in the house as soon as I get this project done. Brick wall

4. And most of all...today started the countdown to July 6th. What's so important about July 6th?? That is the day I have scheduled (as of this morning) to have the Ohio State Highway Patrol inspection done on this rail, in order to get a title and make it street legal!

So I basically have another 28 days to get everything done! Shocked

Honestly, it should be enough time. I gotta wire it, finish mounting lights, horn, one rear seat and 4 point harness, build a center console and install it, and a few other small odds and ends before testing it all out.

Then, I will spend a weekend doing nothing but organizing receipts and build photos, putting them all in an album (or 2 or 3), and just going over everything to make sure all my i's are dotted and my t's are crossed! I will keep everyone posted on what happens with it. No turning back now! Gotta "git er dunn"! Laughing

_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Wed Jun 09, 2010 7:16 pm Post subject: Wiring

What a very productive night! Very Happy

I'd say I am 90% done with my wiring! This is mainly due to the fact that I wired it completely last year for the initial build, with only a few changes for my rebuild this time around.
Tonight, I finish wired the engine, to include alternator, oil pressure and water temp sending units, and ignition.
Then I layed in the main harness, wired in the headlights and front turn signals, brake light switch, battery, electric cooling fans, starter, and fuel pump.
Image may have been reduced in size. Click image to view fullscreen.

The front turn signals are actually the rear turn signals I took off of my Harley motorcycle last year when I switched it over to hard saddlebags. I used them since they seem to match up nicely to the headlights:
Image may have been reduced in size. Click image to view fullscreen.

Bright light! Cool

Here is a pic of a couple of the rubber clamps I used to secure the wiring harness in different places (this shot is of the power lead hold downs for the cooling fans):
Image may have been reduced in size. Click image to view fullscreen.

I already have the wiring pigtail laid in out back to wire in the rear brake lights, turn signals, running lights, reverse lights, and license plate light. I will wire these after I make the mounting plate for all of it. Then I have to build a new center console for all the stuff mounted in my old dash in the picture below:
Image may have been reduced in size. Click image to view fullscreen.

After I got this far....I actually fired the engine for the first time since rebuild began! Very Happy

It sounds so BADA$$! Very motivating!
_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

quadrazer · Posted: Thu Jun 10, 2010 6:57 pm Post subject:

Tonight I focused on the rear end of the rail. Tail lights, reverse lights, plate light and mount. After reviewing my options, I decided to build another guard for the rear of the engine, onto which I could mount a number of the above mentioned items.

The decision to go with an engine guard was simple....to avoid accidents. While it looked cool having all the engine pulleys and such on display in the rear end.....
Image may have been reduced in size. Click image to view fullscreen.

.....I decided to make an aluminum diamond plate cover for the engine guard to protect anyone from accidentely sticking something into the belts (like a finger or something). I started with a rectangular sheet, and fabbed it in from there. Here it is after a little cutting and mock up. You can also see the tail/brake lights mounted above the rear hoop:
Image may have been reduced in size. Click image to view fullscreen.

And a close up:
Image may have been reduced in size. Click image to view fullscreen.

And after all mounting holes were made for reverse lights and plate light/mount, I hit it with the same rhino lining I used on the floor of the rail:
Image may have been reduced in size. Click image to view fullscreen.

Hope to get it mounted tomorrow and all wired up.
_________________
I DID wash my hands....the rest is 'built-in' dirt!

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845

bigrich424 · Posted: Fri Jun 11, 2010 11:11 am Post subject:

Again.... looks great! Question where do you get your diamond plate? And more importantly how do you cut it?

83_WabbitGTI · Posted: Fri Jun 11, 2010 12:43 pm Post subject:

WOW!! What a great build, and fabrication skills to boot!

I love reading through your posts, it's like I'm almost there... Only thing I'm missing is a beer! LOL

Keep it up, can't wait to see this thing finished.... Hey, can you shoot a video of the motor running? I've been wanting to hear that thing roar for awhile now.
_________________
2009-2010 Vice President of SOVW www.sovw.org

"No matter how a VW breaks down.... You can always make it home on Zipties, Ducktape, and JB Weld...."
-Doug Christen, VW Owner

83 Rabbit GTI - 83 Rabbit LS Custom - 63 Westy - 65 Bug - 64 Baja (Herbie's Studly Cousin) - 91 Audi 90 Quattro 20v

Need a VW website built? PM me.

>Help >Donate >Buy Shirts >Register >Log in	See all Samba banner ads \| Advertise on TheSamba.com

Brian's V-6 rail (re)build (pics added daily)
Goto page Previous 1, 2, 3, 4, 5, 6, 7, 8, 9 Next

	Forum Index -> HBB Off-Road	All times are Mountain Standard Time/Pacific Daylight Savings Time Goto page Previous 1, 2, 3, 4, 5, 6, 7, 8, 9 Next
Page 6 of 9