View original topic: 1981 (@wileythewesty) TDI conversion, from ground up Page: Previous  1, 2, 3, 4  Next
Zeitgeist 13 Sat Nov 21, 2020 11:35 pm

Trust me, just cut the entire firewall out. It does nothing that helps you.

MarkWard Sun Nov 22, 2020 8:54 am

You may have another fittment issue. Did Boxeer fabricate the engine mount for the shorter 091 transaxle? Also, the aircooled transaxle had slightly longer CV shafts. I mention this because of my experience.

Not knowing how and where his engine support mounts, it might require you to use his engine attachment location and modify the trans mount and linkage.

I had the opposite problem. My original conversion used the 091ímounting and when I upgraded to the 091/1 trans I had to work around my original engine location. Shortening my trans bracket allowed for the later trans to fit without changing engine location.

So measure twice before you start cutting. Itís solvable.

charleslabri Sun Nov 22, 2020 10:15 am

The mounts do not account for the aircooled differences. Iím chatting with Greg about this for future folks. He said the engine sits about 1/2Ē from the fw. So likely Iíll be about 1.5Ē in the fw.

See on the rear, the gap is exactly 2Ē

In the meantime, I cut out some spacers. Measured up and templated from the brackets. Used a nice thick 3/8Ē steel rectangle tube. If itís good, Iíll powder coat them. This is why Iím near 90% gonna cut that firewall. My rough measurements say with the 2Ē difference Iíll be smacking through the FW

syncrogreg Sun Nov 22, 2020 11:21 am

The input shaft has to be cut as per the KEP directions. 15 and 50 degrees angles are identical because the adapter plate thickness stay the same for both 15 and 50 degree configuration. The amount of shaft to be cut is 7/16"

I did measure and I think 9mm is plenty to be cut and clear the crank.


charleslabri Fri Nov 27, 2020 7:57 am

As I was test fitting my new clutch slave, I noticed the rubber hose from the frame to the slave was totally rotted. It was holding fluid, but I suspect that wouldnít be for long.
I ordered a new braided line from burley that simplified the whole design anyway.
When I got it, it was really different. The nut on the end went from 17mm to 13mm and didnít have the fit I was looking for- it was loose and killed like it wanted to fall out.

So I contacted burley. Itís nice to have some good customer service. He texted me back and we chatted it out. Short of it is that my old design is.... NLA from what I can tell. So I made a new bracket.

Cut it out of some spare galvinized sheet metal, welded it back on- and now I have a proper modern sized mount.

charleslabri Fri Nov 27, 2020 3:23 pm

completed, painted and mounted lil brace for the new hydraulic line:

I also did some test-fitting with the new, nice sound deadening (VB-TSM from Cascade Audio guy in Louisiana. I would sleep on that stuff- it was expensive, but damn it was nice. And I cant rave more about the customer experience buying from Earl. Seriously cool dude.


charleslabri Tue Dec 01, 2020 5:36 pm

Today i did some drillin' and weldin' to migrate the engine mounts back toward the rear about 1.5".

I added a reinforcing plate to the frame, as I felt that it needed just a little-teeny-weenie bit more than what it had with the original mustache bar

hindsight, while i had the welder powered up, i should have filled the old holes, but whatever. im not always a perfectionist.
I did a test fit with the boxeer engine, and this is where it landed the mounts.

Here are is a pic. It was fun.

4Gears4Tires Wed Dec 02, 2020 7:41 am

That's a neat engine lift.

charleslabri Wed Dec 02, 2020 9:04 am

Yeah. Though the seals blew out the other day ;(

4Gears4Tires wrote: That's a neat engine lift.

charleslabri Tue Dec 08, 2020 9:28 pm

Today I did a little repair on the CVs that were in disrepair...

some pow-pow coating on the rear axle rods to make em purdy:

I left the paint off the boot match area as i figured i didnt want to mess with the tolerances. Powpow is no good with that

charleslabri Wed Dec 09, 2020 11:37 pm

Test fit #1
I put the thing in.

Aircooled 091 transaxle (as everyone knows) pushes the engine forward about 1.5"

Some ghetto mounts (on the left) as temporary spacers. Ill likely be cutting the boxeer SS mounts and extending them to fit the aircooled placement.

heres a few pics next day after i worked outside until 10pm with a headlamp in the freezing tahoe winter to mount this thing solo:

erste Wed Dec 09, 2020 11:48 pm

Hell yeah! nice progress!

Why does the 091 Aircooled transaxle push things forward?

charleslabri Thu Dec 10, 2020 6:55 am

erste wrote: Hell yeah! nice progress!

Why does the 091 Aircooled transaxle push things forward?

I believe itís 2Ē longer. Smarter people may correct me if Iím wrong. Possible that it mounts 2Ē further forward than the wbx trans.
I donít have a wbx to compare

?Waldo? Thu Dec 10, 2020 7:57 am

The 091 and 091/1 transaxles are similar length. The 094 5-speed and 094 4wd syncro transaxles are longer. With the switch to the 091/1 and 094 in '83.5/83 the seam between engine and trans moved rearward presumably in order to give more room for the nose of the 094 5-speed trans (and probably for the eventual 094 4wd syncro trans). That change can also be seen in the engine mounting position and carrier bar difference between the '82 diesels (091 trans) and the '83 diesels (094 5-speed).

Zeitgeist 13 Thu Dec 10, 2020 8:20 am

You can also just modify the trans mount to shift the drivetrain rearward. My van uses a DK trans, and I've added spacers to both lower and move everything back. Definitely easier than modifying Greg's mounts.

charleslabri Thu Dec 10, 2020 9:57 am

Quote: You can also just modify the trans mount to shift the drivetrain rearward.

but then youd gotta run WBX shifter, yes?

Honestly, its not hard to mod gregs mounts. Im gonna slice and splice them with stainless.

?Waldo? Thu Dec 10, 2020 10:00 am

You might need to lengthen one linkage rod. I don't think you'd need to do any other changes to the shifter/linkage.

Zeitgeist 13 Thu Dec 10, 2020 11:45 am

I'm running a modified 091 rear shift rod mated to a stock 091/1 front section. Shifts are buttery smooth.

Vanagon Nut Thu Dec 10, 2020 2:28 pm

Great to see the fit pics. FWIW, images showing length differences of my old trannies:

air cooled vs wbx front mounts. ~ 1 - 1.5" difference

air cooled vs wbx tranny. WBX: ~ 0.8" longer. It seems the bigger factor in length increase was at WBX mount stand offs:

Overall, I saw ~ 2.25" difference


charleslabri Thu Dec 10, 2020 2:58 pm

those trans pics are awesome. i never had that much context on the sizing differences.

that should be a sticky

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