T3 Full Flow DIY (post your pics!)

icelancer

I had a rather difficult time finding pictures to help with my gb246 full flow install. My goal is to try and get all the t3 full flow info in one spot to make this a simple modification for anyone. Make sure to post your pics! I don't have the engine in the car yet so I will update this again later.

Special tools needed:
3/8 npt tap
9/16 drill bit
1/4 npt tap
7/16 drill bit
Ratchet with 12point socket for taps
Grinder
Dremel with sanding drum or belt sander
Drill with a level or someone to tell you if your lined up

Supplies needed:
Penetrant (like liquid wrench or wd 40)
Red thread locker ( or blue if your feeling lucky)

Full flow kit:
1 hex plug (1/4 pipe)
5 street 90 (3/8 pipe)
2 male flare to pipe (3/8 pipe-3/8 flare)
2 20'' female flare hoses (3/8 flare)
1 1'' pipe nipple (3/8 pipe)
3/8 Filter tree housing
Gb clearanced oil pump cover (if you know of other options let me know)

The process:
1. Remove oil pump with puller
2. drill outlet side of oil pump with 7/16 drill. (Top left hole)
3. Tap hole with 1/4 npt tap. Go slow and use penetrant or cutting oil to lubricate. Turn 1/4-1/2 at a time then back off to clear metal. Do this until plug inserts and does not interfere with case.
4. Remove case plug for oil gallery and pressure relief on bottom left. Make sure to stuff something to keep the magnesium flakes out of the engine down the gallery.
5. Find a reference for level ( use a laser level or a person or something) and drill the gallery with a 9/16 bit. You have to drill a little past where the old oil pump gallery is.
6. Tap the hole with the 3/8 tap. Go slow as engine cases are not cheap. Don’t tap too far because you want the fitting to get tight at the correct spot. This requires trial and error.
7. Grind a 3/8 90 fitting so it is a round a possible but can still be turned with a wrench.
8. Clearance the gallery to the right (i used a dremel with larger sanding drum) until the fitting can be turned 360 degrees.
9. You have to grind the hole you tapped shorter so the fitting can screw in more turns. Just use a 4" grinder and finish up with dremel. Make it level to where the case is flat.
10. Test fit the modified 90 and make sure it screws in almost all the way and gets tight. End should point around 10 o clock, slightly higher is ok but lower is not
11. Remove all metal debris and insert the modified 90 with thread locker, and install the oil pump, cover, and pressure relief. Make sure to lube pump gears for prime.
12. Grind the bottom left pump cover nut until it doesn’t hit on the back fan shroud.
13. Grind the corner off another 90 and install into oil pump cover, combine this with another 90 and make it fit a tight as possible to the case.
14. Check clearance on moustache bar and cut a hole accordingly.
15. Install pipe nipple into the 90 combo along with another 90 that has been clearance as small as possible on the back facing the mount.
16. Check moustache bar fitment again and grind it thinner where it contacts the lowest 90. I used small washers to minimize grinding.
17. Install all lower fittings with thread locker ( good idea to test where the hoses are going to go before doing this)
18. install another 90 onto upper fitting and check hose placement IAW lower hose. Apply thread locker after fitment is assured.
19. Depending on how much your upper 90 screws in you may have to clearance the webbing on the fan shroud.

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

_________________
71 squareback (1904 A/T)
71 super beetle (1904 M/T)
B5.5 wagon M/T daily driver
SB for squareback or san bernardino....who knows.

W1K1 · Posted: Mon Dec 22, 2014 4:48 pm Post subject:

send case to brothers for Full Flow oil inlet and outlet welded in.
install stock pump, plumb hoses and filter, done.
No extra tools needed.

the more fittings you have the better chance you have for leaks
_________________
http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

jonnynotch · Samba Member Joined: September 08, 2005 Posts: 32

Had my case tapped at a local shop.[/img]

rosevillain · Posted: Mon Dec 22, 2014 8:19 pm Post subject:

jonnynotch · Samba Member Joined: September 08, 2005 Posts: 32

Thanks for props man! Engine went into this.

1969 auto Notch. Runs real nice...but needs to be bigger though. Here's hoping Santa brings a new crankshaft.

Merry Christmas

Max Welton · Posted: Mon Dec 22, 2014 9:34 pm Post subject:

Verrry Nice!

Max
_________________
1967 Type-3 Fastback
Under the Knife https://shoptalkforums.com/viewtopic.php?f=24&t=151582
Home Stretch https://www.thesamba.com/vw/forum/viewtopic.php?t=767836

icelancer · Posted: Sun Dec 28, 2014 5:45 pm Post subject:

Thats a very clean engine jonnynotch!! I was going to make mine look nice...but I didn't cause im lazy. Heres my full flow finished.

_________________
71 squareback (1904 A/T)
71 super beetle (1904 M/T)
B5.5 wagon M/T daily driver
SB for squareback or san bernardino....who knows.

jonnynotch · Samba Member Joined: September 08, 2005 Posts: 32

Thanks Ice!
I would very much like to see some pics of your engine installed...curious to see how the filter will mount.

Are you running the stubby filter or full size?

This a pretty cool mod. Hoping we get more pics from the type III crowd. I curious to see how others run theirs.

icelancer · Posted: Sun Dec 28, 2014 10:08 pm Post subject:

I am curious to see how the filter will fit too! Hopefully we will find out before next weekend. I have a fram hp1 filter but I may have to use a smaller one.
_________________
71 squareback (1904 A/T)
71 super beetle (1904 M/T)
B5.5 wagon M/T daily driver
SB for squareback or san bernardino....who knows.

W1K1 · Posted: Mon Dec 29, 2014 9:44 am Post subject:

I'm not a fan of Fram
the stubby is a K&N HP1002, Mobile M1-102, wix 51348XP
_________________
http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

raygreenwood · Posted: Mon Dec 29, 2014 12:57 pm Post subject:

icelancer · Posted: Fri Feb 13, 2015 12:21 pm Post subject:

My square is apart again but here is my tee for oil temp/pressure to my DD multi function gauge. I used basic 1/8 plumbing parts and it leaks like hell. I would not recommend this.

_________________
71 squareback (1904 A/T)
71 super beetle (1904 M/T)
B5.5 wagon M/T daily driver
SB for squareback or san bernardino....who knows.

W1K1 · Posted: Fri Feb 13, 2015 4:54 pm Post subject:

that's because you are mixing M6 metric thread sensors with 1/8" npt threads
_________________
http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

icelancer · Posted: Sun Feb 15, 2015 11:39 am Post subject:

I didnt think of that. I will have to measure and find out.
_________________
71 squareback (1904 A/T)
71 super beetle (1904 M/T)
B5.5 wagon M/T daily driver
SB for squareback or san bernardino....who knows.

airhead22 · Posted: Wed Feb 18, 2015 11:43 am Post subject:

Heres mine version.

My build
http://www.thesamba.com/vw/forum/viewtopic.php?t=323523&highlight=

6 years since build and no issues.

racoguy · Posted: Fri Sep 18, 2015 10:29 pm Post subject:

Here's my version, didn't like the idea of welding fittings on a brand new unwarped case and wanted something which could be removed completely if needed.
No clearancing of any kind needed on the fan housing, I won't be needing the rear hanger bar but even that could be worked around.
Lower is a ....dare I say it Empi steel cover with a custom stainless pipe and fitting to clear the housing.
Top is a banjo fitting with a custom stanless pipe and a bracket welded between the two for rigidity.

_________________
https://www.facebook.com/pages/West-Worx/460154187360186

Max Welton · Posted: Sat Sep 19, 2015 6:23 pm Post subject:

Very nice.

Max
_________________
1967 Type-3 Fastback
Under the Knife https://shoptalkforums.com/viewtopic.php?f=24&t=151582
Home Stretch https://www.thesamba.com/vw/forum/viewtopic.php?t=767836

Aaron M265 · Posted: Sat Sep 19, 2015 6:57 pm Post subject:

My 2276cc with full flow.

My 2028cc with full flow.

The fan housing is sliced and rewelded to clear the hoses. Anyone that can weld magnesium can do that easy enough. The 'O' Berg is mounted onto a bracket to the side of the case. Makes installation etc easy.

Yes all the purple paint has been removed now. I was young and stupid when I did that. Now it's all bare / polished alloy and zero maintenance (older and wiser!).
_________________
Aaron

http://1500notchback.blogspot.com/

Need to contact me? Email is faster than a PM - [email protected]

For T3 Panel Van information:
http://www.thesamba.com/vw/forum/viewtopic.php?t=389465

t3kg · Posted: Sat Sep 19, 2015 7:52 pm Post subject:

VWporscheGT3 · Posted: Tue Sep 22, 2015 8:34 am Post subject:

this last one is my favorite of all time... Freaking awesome. its just too bad it doesn't look like it would work with mustache bar cars...
_________________
Schnell, SCHNELL!

I like being wrong, Because, it is another opportunity to learn. If you stop learning from your mistakes than what is the point?

If you have any questions about Forged ICON 4032 VW pistons just shoot me a line.


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