TheSamba.com :: View topic

Mon Feb 06, 2006 9:10 pm

{EDIT: With the permission of the site administrator, I have chosen to use this thread to show various techniques and methods I use in my shop on an ongoing basis, such that others might be able to benefit and possibly use them as well. This is not intended to promote or showcase any of my Zarwerks products and no business will be discussed here. I can be reached via e-mail at [email protected]

- John H }

Mon Feb 06, 2006 10:23 pm

Cool, would that be the 53 only manifold that I need for my vert?

Mon Feb 06, 2006 11:54 pm

Or would it be the one that I need for my hard top? :lol:

Tue Feb 07, 2006 7:23 am

Could be. I'll be making 3-4 of them this pass.

Can anybody who has on original (Bob, Dave?) tell me what markings they have on the jacket. The original one I have (seen behind) is a 36hp one built for a 28mm carb. I know that the original "zwitter" ones were for 25hp, wondering what they had for logos, markings, etc. on the jacket.

Also, the original one I have has the "grooved" jacket, to the 25hp versions have those? I could pretty easily file that into my repros....

Tue Feb 07, 2006 7:33 am

I'll look for you tonight John........I don't remember any. :?

Tue Feb 07, 2006 7:36 am

Thanks Bob. You might need to use a mirror, the later ones (36hp) were embossed on the back of the jacket.

Or you could justpull the intake and send it to me for inspection :lol:

Tue Feb 07, 2006 8:59 am

johnshenry wrote: Thanks Bob. You might need to use a mirror, the later ones (36hp) were embossed on the back of the jacket.

Or you could justpull the intake and send it to me for inspection :lol:

I'll try the mirror. :wink:

Tue Feb 07, 2006 10:29 am

johnshenry wrote: Could be. I'll be making 3-4 of them this pass.

Can anybody who has on original (Bob, Dave?) tell me what markings they have on the jacket. The original one I have (seen behind) is a 36hp one built for a 28mm carb. I know that the original "zwitter" ones were for 25hp, wondering what they had for logos, markings, etc. on the jacket.

Also, the original one I have has the "grooved" jacket, to the 25hp versions have those? I could pretty easily file that into my repros....

My 53 is a 25 horse but it has an accelerator pump carb, is that correct? Or should it have the non-accelerator pump carbs like the split bugs?

Tue Feb 07, 2006 10:59 am

I believe it to be with the pump. I have a 28pci carb on my car and a while back had it critiqued by Bob. He said it was correct or 'fine'. (fine means good with his high standards :wink:)

Tue Feb 07, 2006 1:06 pm

buggen wrote: johnshenry wrote: Could be. I'll be making 3-4 of them this pass.

Can anybody who has on original (Bob, Dave?) tell me what markings they have on the jacket. The original one I have (seen behind) is a 36hp one built for a 28mm carb. I know that the original "zwitter" ones were for 25hp, wondering what they had for logos, markings, etc. on the jacket.

Also, the original one I have has the "grooved" jacket, to the 25hp versions have those? I could pretty easily file that into my repros....

My 53 is a 25 horse but it has an accelerator pump carb, is that correct? Or should it have the non-accelerator pump carbs like the split bugs?

The pump is correct.

Tue Feb 07, 2006 2:09 pm

Quote: My 53 is a 25 horse but it has an accelerator pump carb, is that correct? Or should it have the non-accelerator pump carbs like the split bugs?

Interesting. Because this is a "transitional" intake. I believe it came after the 36hp style looking one, that had 25hp endcastings and 26mm carb flange (no flare on the carb riser tube just under the flange, ID of the flange is 26mm). So it (the "'53 Only" one) for a 25hp engine, but with a 28mm (accel pump carb, flared riser) .

The one that came after it was the "701E" 36hp intake.

While the heat riser that came on the 25hp/26mm intake and "701E" intakes was basically the same shape, the tubing is of a different diameter. The tubing on the 701E is thicker, and greater wall thickness.

The heat riser on the "original" one I have seen in the pic is thin, however the end castings are for 36hp, not 25. Go figure.

I'm going to make up a table that explains all the changes, and post it at the Zarwerks site. I'll have you guys review it, hopefully you are not too shy to point out anything that mightbe incorrect.......

:lol:

Tue Feb 07, 2006 5:57 pm

johnshenry wrote: Thanks Bob. You might need to use a mirror, the later ones (36hp) were embossed on the back of the jacket.

Or you could justpull the intake and send it to me for inspection :lol:

There doesn't seem to be anything there.....I used the mirror and felt along with my fingers where I could and NOTHING. No part number or VW stamp embossed; at least, none I could note. The "groove" between the two pipes is more pronouced through the jacket.....unlike the 36 that doesn't have much definition at all. I have a 36 and it is not the same. Even on the front, the jacket defines the two pipes and does not obscure them at all; almost like a wet towel would show the shape of the two different pipes.

Tue Feb 07, 2006 6:00 pm

johnshenry wrote:

Looking at your picture again......the one in the back shows the distinction between the two pipes through the jacket. Is that a real one? Because it really looks correct. :?

Tue Feb 07, 2006 6:03 pm

johnshenry wrote: Could be. I'll be making 3-4 of them this pass.

Can anybody who has on original (Bob, Dave?) tell5{hey have on the jacket. The original one I have (seen behind) is a 36hp one built for a 28mm carb. I know that the original "zwitter" ones were for 25hp, wondering what they had for logos, markings, etc. on the jacket.

Also, the original one I have has the "grooved" jacket, to the 25hp versions have those? I could pretty easily file that into my repros....

Now I see what you mean.......mine looks just that.....at least from the front.

Tue Feb 07, 2006 6:12 pm

Thanks Bob.

I actually have a 36hp one ("701E") with that pronounced groove, and I started to use it to make the '53 one, then go figure, I find a crack in the jacket on the back! Doesn't that suck!

I could actually file the groove in and after a bead blast, it would look pretty good.

So, Bob, you said you have the groove, no numbers or logos that you can feel.

And your engine is 25hp right?

And do you have a 28mm carb flange with the flare under it?

Thanks, I'm trying to get as much info as I can.

Dave Haviland, if you are reading, you have one of these too, what does yours have???

Thanks...

Wed Feb 08, 2006 3:26 pm

johnshenry wrote: Thanks Bob.

I actually have a 36hp one ("701E") with that pronounced groove, and I started to use it to make the '53 one, then go figure, I find a crack in the jacket on the back! Doesn't that suck!

I could actually file the groove in and after a bead blast, it would look pretty good.

So, Bob, you said you have the groove, no numbers or logos that you can feel.

And your engine is 25hp right?

And do you have a 28mm carb flange with the flare under it?

Thanks, I'm trying to get as much info as I can.

Dave Haviland, if you are reading, you have one of these too, what does yours have???

Thanks...

That's the way I see it John. Pronounced grove, no markings, 25hp, 28mm carb flange with slight flare.

Wed Feb 08, 2006 8:28 pm

Couple more pics (from my crappy "shop" camera).

Finished the butt welds on the first one, LOTS of flat filing. Made a second and cut parts for a third. Still need to finish the welds, mill the endcastings for 25hp, media blast, paint and bake.

The heatrisers have to be blocked BTW, as the heatriser is dimple-rolled along its top edge to sit "squished" against the bottom of the intake runner, the "extension" heatriser section cannot be butt welded where it touches the intake runner. While it is unlikely that exhaust gases would escape out of that tiny crack (which you can't see), I cannot take risk. Even if the amount of gas that escaped was small and harmless, it would probably discolor the intake runner.

Since most people only drive these early cars on warm, nice days, it shouldn't matter. Most people will have driven these cars for years with completely blocked heat risers and never even knew it.....

Wed Feb 08, 2006 10:21 pm

Looking good. :D Thank god for guys like you John. You're a talented man.

Wed Feb 08, 2006 10:29 pm

Hi John. You are really doing a great job on these manifolds. I found another one .... 26mm head and 28mm carb, and I think there are some numbers on the rear of the jacket. I'll try to check it out tomorrow or Friday. Thanks for your efforts at Zarwerks.

Thu Feb 09, 2006 7:49 am

I figured you might jump in here Rick. :lol:

Thanks for you paitience, the first one of these is yours.....

Should be done in a couple weeks....