'66 bug tdi conversion plus aluminium stuff!

[Floyd1966]

Hi,
Thanks for looking

This is quite a long story, and it's got a long way to go yet!

Back in 1991 I bought a '66 bug that I found in a field behind a workshop. It had been there for 8 years following having a new clutch fitted. The car owner couldn't pay the bill, so it stayed there.
I paid the clutch bill and the car owner gave me the car. It was rotten! I taught myself to weld and fixed it up.
I used it as my daily driver gradually uprating the performance.
I fitted disc brakes, bigger rear drums, lowered all round, 12v conversion, and went through many engines. The last engine I had was a 1776 I built myself using all the right stuff to make it fast and reliable.
However by this time I had two young children and driving around in a very noisy cold car lost its shine!
The bug was taken off the road and put in the garage in 2011.
Every time I went in the garage I would look at it and wonder what to do with it. I'd had it as part of my life for so long I couldn't sell it. But it was a waste sitting in my garage.

Meanwhile I'd changed jobs and started working for a camper restoration company MV Engineering, who specialise in tdi conversions in T25's. Mario, the owner had a 3 cylinder turbo diesel engine from a vw polo ( fox?) he was putting into a bay window. 1.4 litre, 75 bhp, 140 ft/lb torque 60-65 mpg, all as standard. With a different turbo, bigger injectors and a remap you can see over 100 bhp, 200 ft/lb torque and still get 55-60 mpg!

That got me thinking........



I'd even get a proper heater.........

[Floyd1966]

So I bought a 2000 1.4 tdi vw polo with 80,000 miles for not a lot as the bodywork was trashed. Somehow this engine is going in the back of my bug!

I bought an adapter kit and after many an hour trimming here and there got it in!

I also removed most of the sheet metal from the front end to make way for the radiator.

[Floyd1966]

I made up a frame for the front body mount and fuel tank. I've raised the tank by about 1 1/2" to aid air flow underneath.

Now, to get the air into the radiator area I've done something a bit different

I didn't want to cut holes in my bonnet ( Hood?) or the front apron. So I've made a aluminium front bumper with built-in airscoops....

[Floyd1966]

I wanted a ridge through the bumper for both looks and added strength. This is the profile I was after

First some 1050 1.5mm aluminium was cut and bent round a 3/4" pipe

Then the edges went into the shrinker to pull it round into a curve

This has the effect of causing the middle to dip in

So it needs to be stretched on the power hammer

[Floyd1966]

Now to make the ridge.
A different tool is used in the power hammer

Once the bumper has passed through this it looked like this

A couple of scoops were made and welded in

I decided to make a new skin for the front apron, keeping most of the structure the original steel.
First it was stretched in the English wheel

Then the edge shrunk

And then solid riveted to the apron. A coat of special paint was used to prevent chemical corrosion between the aluminium and the steel

A trial fit to the car, not quite the right shape yet, but getting there

[Floyd1966]

By this time I had been offered a job at one of the best metalworking shops in the UK, www.Metalcraftltd.com, hence the cool tool access! Lol

[enjoyther1de]

Very cool!
_________________
HBB took me to BBV.

[Floyd1966]

Made a start on the front fender
This is the rear of it taking shape

I'm using the old wing as a guide.

I'll make it in five or six pieces then tig them together. I'm using 1.5 mm 1050 aluminium

[caleb0101]

[Floyd1966]

No, my originals are in good order. My front fenders are reproduction and starting to rot.
However once this car is finished I'm starting a Hebmuller replica which will be all aluminium built on a bug chassis with a hidden roll cage. Hopefully I'll be on this next year.

[Floyd1966]

well, it's running



https://www.youtube.com/watch?v=M316s-VlWKs

https://www.youtube.com/watch?v=M3kqdCOAMGw

now I realise that in the USA this may seam an odd conversion, but here in UK gasoline is so expensive ( £1.20/litre = $8 per gallon )
Also the 3 cylinder diesel engine is quite common over here. In fact, many new cars are being made with 3 cylinder turbo engines, both diesel and gasoline

[mukluk]

Congratulations! How much more is there to do until it's roadworthy?
_________________
1960 Ragtop w/Semaphores "Inga"

[Floyd1966]

Thanks
Not too much left to do.
I need to fabricate and fit a new rear bulkhead and rear floor ( behind the back seat) as I've had to butcher it quite a lot!
I also need to sort the engine lid as it can't close. I'll probably either make a bulge or cut a scoop in it ( like the old Empi ones) I could just fit standoffs but I don't really like the look.

[Akantares]

This is amazing. How hard was this to do? I've been mulling around with this idea for a while. Please keep us updated!
_________________
Felix the Flying Deutschmann: 1969 Savannah Beige Beetle with 1600DP engine

[Floyd1966]

Thanks. How hard it is depends on your skill set and the people who can help. I was fortunate that I know the leading tdi conversion people in the UK, MV Engineering. They work mainly on T2 T3 and T4, but their knowledge and help was the difference between success and failure.
I've built quite a few engines before, even a home made fuel injection system. My attitude is that you can do anything you want to with the right help, and Google!
The hardest thing for me was working out all the incompatible things, bellhousing too small, clutch, starter ( hardest of all!). The wiring was one of the more enjoyable sides of it. It did take three days, but I was rewarded for my patience and methodical approach with an engine that started first turn of the key.
I'm hoping to get the rest of the car done before Christmas, fingers crossed!

Thanks for your interest

[Floyd1966]

Thought I'd do a little update.

I finished the engine conversion a while ago. Since then I have done thousands of miles in it trouble free. On a run I can get 87mpg out of it if I stick to 50mph.
I took it to a drag strip the other week and recorded a 17.49 @ 73mph. At the 1/8th mile I was doing 62mph so as you can work out my gearing needs looking at. Still not too shabby for a 1.4lt diesel

I am now concentrating on the bodywork. I'm going all hand made, no bought panels and as much aluminium as I can.

I have already done the engine lid, front and rear valances and drivers door skin from aluminium.

The engine lid was made with a different profile in order for it to clear the engine.

I'll post up some photos in a bit.

I'm trying to keep it as a rolling restoration for as long as possible because I really don't want to stop driving it! Lol

I haven't painted the new panels yet, just bare aluminium. But I will paint it when I've finished. Whenever that is!

[Floyd1966]

[Floyd1966]

[Beetlebaum]

Holy cow, this is awesome!! My brother wants to put a TDI engine in a Ghia--he owns a '98 Jetta TDI with the 1.9 liter engine in it at the moment and loves it. I'm going to send him the link to this thread.
_________________
1973 Super Beetle
2003 New Beetle
Post your Super here: http://www.thesamba.com/vw/forum/viewtopic.php?t=331999
Beetle Bums VW Club Member

[DieselDork]

Heck yeah! This is absolutely killer! Definitely gonna have to do a Ghia!