My suby 2.5 conversion

streetbuggy8804 · Posted: Mon Jan 16, 2012 8:56 pm Post subject:

Btw the opening is 24x9. Radiator is 12x 24.5 total. I think that should cover 40% if my math is any good. 2 fans is definitely on the list. Had one on hand.

Baja68 · Posted: Tue Jan 17, 2012 10:10 am Post subject:

Ok i have a little time so I will post some more pics.

I ordered a factory harness to match my engine that came out of a 2002 forester standard trans.

the harness cost me 200.00 it was a complete in good shape harness

here is a pic after I had unwrapped the harness and cut away the parts of the bulk head harness that I did not need. the part on the left is what was left over.
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After that I pined out the harness and followed the factory ECM I/O diagram to lable and find all the parts that I need to operate the engine only.
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SO the harness still needs the data link connector wired in to it and the ignitor so it is not yet completely converted for my application but its close.

Here is the fuel pump location I still am waiting on the fuel filter parts to come in the mail.
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When I flipped the intake the coil would not mount on top the intake like it was designed to do so I put little aluminum spacers in to make that work.
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put a solid mount with a rear trans strap in
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I am going to put in a kafer bar aswell.

Here is a pic of the rear bumper I planned to put the radiator in ( after reading the above post of insufficient air flow in the rear I am considering a front mount. Also the rear bumper is causing problems being to close to the oil filter and water inlet at thermostate housing.
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I plan to set my exhaust up like the pic below
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I ordered a forester exhaust manifold 70.00
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I plan to cut it off and weld on mufflers I like the looks of these
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Also the header I ordered once installed it could be used in its current factory state if some one was wanting to do a merged into 1 pipe like a sidewinder or something.
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I plan to mock the body up and play with the front radiator options and the exhaust location options.

I dont like the rear bumper and radiator blocking the veiw of the motor but I felt like if I could get enough air flow it would be the easiest way to set it up.

But I am still in the design and fabrication mode so nothing is solid yet.
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diffdude · Posted: Tue Jan 17, 2012 12:49 pm Post subject:

You can see in my link I have my radiator 1 1/2 inches off the firewall with no hole through and mine never gets off 180 deg.

http://www.thesamba.com/vw/forum/viewtopic.php?t=4...p;start=40

streetbuggy8804 · Posted: Tue Jan 17, 2012 1:51 pm Post subject:

Hey Baja, that pick of the buggy with dual exhausts is almost exactly what I had planned on doing with mine. Do u know if that system is somehow merged or is it more like the normal vw style " dual cannon" exhausts?

didget69 · Posted: Tue Jan 17, 2012 3:31 pm Post subject:

streetbuggy8804 · Posted: Tue Jan 17, 2012 4:12 pm Post subject:

Who knew there was such thing as a radiator location Nazi.

Andy P · Posted: Tue Jan 17, 2012 4:30 pm Post subject:

gr8cobbler · Posted: Tue Jan 17, 2012 4:33 pm Post subject:

Hard to argue with success....if it works and keeps it cool it sure is practical. Fans may be sufficient to draw enough cooling air through it?

It sure looks a lot better there on the firewall than it will behind the engine or rigged up front. I always liked the idea of twin radiators stuffed into vented side pods from a purely asthetic point of view.
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Gary

Being a cheap old fart is just a front for my actual lack of money. Smile

diffdude · Posted: Tue Jan 17, 2012 4:49 pm Post subject:

The nice thing too is that the fans are on a factory watercooled temp switch and they cycle on and off. They dont run all the time.
I do think the motors loose alot of heat from been out in the open.

didget69 · Posted: Tue Jan 17, 2012 6:19 pm Post subject:

didget69 · Posted: Tue Jan 17, 2012 6:23 pm Post subject:

Baja68 · Posted: Tue Jan 17, 2012 7:43 pm Post subject:

Here is another pic of the above buggy with the rear mount radiator.
This is what I was going for.

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We will see what happens with the cooling when I get mine finished I will be the guinea pig for the rear mount Smile

Streerbuggy,
Ya its not merged eghuast that is shown in that buggy as far as I can tell. I am unsure what the effects will be of running it dual. The techs at the shop seem to think it will be fine on a non turbo.

And I guess you can let us know how your design cools when its up and running. It will be interesting to see the results on that radiator location.

I decided to use the factory ECM and harness for mine no tuning needed plug and play for the most part short a handle full of wires and a few relays.

I can't wait to fire mine up Twisted Evil

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My Build Page http://www.thesamba.com/vw/forum/viewtopic.php?p=3852984&highlight=#3852984

streetbuggy8804 · Posted: Tue Jan 17, 2012 7:57 pm Post subject:

Where did you get that pic? I would love to see that build thread. Btw outfrontmotorsports does only rear mount radiators.

Andy P · Posted: Wed Jan 18, 2012 12:05 am Post subject:

Why is there an argument here?
If you can make a rear mount radiator work then all power to you.
But most of the factory radiators people are using are mounted at the FRONT of the car from the factory.
You can't fight that fact.
Aside of Renault 10s I can't think of another car that's watercooled, rear engined AND rear radiatored.
Please add to the list if you can.
You can't get around the fact that when the radiator is at the front the cold air is being RAMMED into it as you drive forward.
No one here wants to rain on other's parades but we are trying to make sure you don't cook your motors if you can possibly avoid it.
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GS guy · Posted: Wed Jan 18, 2012 5:09 am Post subject:

I think one problem is we all read about build threads where the radiator is installed in the back or under the back seat area, and eventuially the thread dies out and you never hear how well it really worked out - or not. A few exception to this, like Petew, who did follow up after considerable time trying to make it work with good follow-up details.

I guess the bottom line is, the rear mount seems to be marginal (maybe OK for a lower powered N/A installation?), while a front mount is a sure deal and can likely get by with a smaller radiator. I've never read of a front mount radiator install overheating or having any high running temperature problems. For the rear mounts it always seems like the thread leaves off with the builder trying to design and install better ducting to improve cooling.

Also, IIRC, the "wheelie" buggy posted above was switching to a front mount radiator becasue of issues, despite the clean install and attention to detail obvious in the pictures. Never heard if the radiator swap was completed and think he was trying to sell the buggy - a few years ago?

Jeff
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70's vintage Deserter GS buggy - undergoing transformation to Super GS!

gr8cobbler · Posted: Wed Jan 18, 2012 6:07 am Post subject:

A couple of options. Two different machines pictured, just happened to find two orange ones... Rolling Eyes

As I mentioned before I like the look of the vented sidepods, but I'm guessing that they had issues or maybe it was more efficient, cleaner and/or simpler to incorporate the radiator into a rear spoiler wing? Just some visual food for thought. Smile

_________________
Gary

Being a cheap old fart is just a front for my actual lack of money. Smile

Andy P · Posted: Wed Jan 18, 2012 6:57 am Post subject:

gr8cobbler · Posted: Wed Jan 18, 2012 7:52 am Post subject:

I'm a real fan of KISS (Keep It Simple Stupid in this case, not the rockers from the late 70's) Bottom line I'm also in the Function over Form crowd too. But the real challenge is to built something that not only works well but "looks" right too. Awesome airflo can be achieved with a billboard mounted radiator staning upright on the rollbar but you'd find yourself in the abortion thread in a heartbeat. Shocked

Part of what i really like about these threads and this website is that we learn a lot from each other about what has been done and what works and what doesn't, the archivea are full of pictures and comentary to draw on and help improve outcomes. We don't need to repeat errors, we (I?) can learn from others mistakes.

Hate it when great build threads fade away, it's like missing the last chapters of a book or the last ten minutes of a movie.... left hanging. I can think of several right now... Don't fail us with this one Baja68 Cool

_________________
Gary

Being a cheap old fart is just a front for my actual lack of money. Smile

Baja68 · Posted: Wed Jan 18, 2012 10:59 am Post subject:

No worries this is getting done I will not stop untill it is. Since I have it set up for rear I plan to stay the corse but I will be mocking up the body and looking into the front radiator location further one of the issues with the front is I have bought a radiator for the back and if I put one in the front it will most likely need to be smaller/shorter.

So if I have to cut the hood to make a front radiator work now would be the time.

We will see I did the body work over the last few months and it turned out bad there was contamination in the air line or the fact it was painted outside was the cause but it was fish eyed fierce. So I am sanding back down and getting a friend to do it in a both.

And the flake did not turn out as evenly spread as I would have wanted. In the end it was a 10 foot car and thats what I had before I started and was unacceptable to me.

Here is a pic after it was done like I said looked good from 10 feet Sad

So my new plan is Gun metal with a carbon fiber wrap on the instament panel and exhaust with carbon fiber wrap mufflers and a carbon fiber steering wheel.

What I picture in my mind should look sharp hope it turns out like I picture it. Smile

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streetbuggy8804 · Posted: Wed Jan 18, 2012 12:36 pm Post subject:

Man great minds think alike.
Carbon fiber dash
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I plan on doing a carbon fiber exhaust set up as well. Outfronts motorsports has a carbon fiber laminate wrapped timing belt cover. A little steep at 240 though

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My suby 2.5 conversion
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