TheSamba.com :: View topic - 1981 (@wileythewesty) TDI conversion, from ground up

Thu Dec 10, 2020 3:23 pm

Thanks. Bear in mind though that given my foray today into auto tranny Sinka's, any rep I had is now tarnished. So, take my measurements for what they're worth. LOL. ;) Actually, I took care line up the clutch housing faces for those pics so measurements are fairly accurate.

If you ever go to a WBX tranny, but keep engine at air cooled position, some pics of how I adapted the WBX tranny to air cooled engine position. Flipped mount idea was courtesy of ?Waldo?. Rereading my notes, I would've done things differently and better but this was first time at this with beginner level fabricating skills so.....

https://goo.gl/photos/GXTagUdjdekict8R7

Even with removed material, mount is still fine afaik. e.g. no cracking.

Neil.

Thu Dec 10, 2020 5:01 pm

I think it would be a much better idea to move the engine/aircooled tranny rearward to the wbx position now. Less work overall for the long term.

Mark

Thu Dec 10, 2020 5:13 pm

It will give easier access to the clutch slave and starter. This is especially true if you delete the firewall.

Thu Dec 10, 2020 7:50 pm

I cut the firewall out a few weeks ago

Thu Dec 10, 2020 10:06 pm

When Mark tells you some tips to make your project move forward, it carries a whole lot more weight than my meager suggestions. He's probably forgotten more than I'll ever know about these vans. I strongly suggest you follow his recommendations.

Fri Dec 11, 2020 5:57 am

Zeitgeist 13 wrote: When Mark tells you some tips to make your project move forward, it carries a whole lot more weight than my meager suggestions. He's probably forgotten more than I'll ever know about these vans. I strongly suggest you follow his recommendations.

Referring to marks comment about the CVs?
Currently if I extend Greg’s brackets (which do not work for aircooled tranny position) I keep everything bone stock.
If I modify the trans location to be more like a wbx and fit Greg’s mounts, I end up changing 1) trans mount 2) shift linkage 3) CV angle 4) clutch slave position.
Seems a no brainier to keep stock locations and modify Greg’s mounts.

After being pretty active on the forum here for about a year, I agree... mark is def weighted in his knowledge of vans. A legend

Fri Dec 11, 2020 9:26 am

One other thought is that the 091 trans was only available here for around 2.5 years, so they're kinda rare. They're also a bit weaker than the 091/1. Your new engine produces monster level torque, so if you grenade your current trans in the future, it might be difficult to locate a similar unit as opposed to the stronger and more readily available 091/1. If you move the trans mount now, you'll be able to swap in any trans, including a five speed 094. Options.

Btw: regarding the CV angle, with the drivetrain shifted rearward my axles are now a straight run to the hubs, rather than angled forward as they were in the aircooled donor van.

Fri Dec 11, 2020 10:27 am

Ive thought about this.. i did some serious beefing already to the 091 trans.

My plan is that if the trans grenades, likely ill just turn my ride into a syncro.

Fri Dec 11, 2020 12:09 pm

charleslabri wrote: My plan is that if the trans grenades, likely ill just turn my ride into a syncro.

In that case you will need to move the engine rearward to the later position.

Fri Dec 11, 2020 12:58 pm

charleslabri wrote: Ive thought about this.. i did some serious beefing already to the 091 trans.

My plan is that if the trans grenades, likely ill just turn my ride into a syncro.

Want to buy some parts?

Fri Dec 11, 2020 2:12 pm

?Waldo? wrote: charleslabri wrote: My plan is that if the trans grenades, likely ill just turn my ride into a syncro.

In that case you will need to move the engine rearward to the later position.

ez

Fri Dec 11, 2020 2:13 pm

pjn_wyo wrote: charleslabri wrote: Ive thought about this.. i did some serious beefing already to the 091 trans.

My plan is that if the trans grenades, likely ill just turn my ride into a syncro.

Want to buy some parts?

if i had anywhere reasonable to store syncro parts, id say yes. But r/n i dont ;(

Tue May 04, 2021 6:52 pm

whew, ok. I am back at it after the winter.

finished off the drilling on my airbox today from the vanistan fresh air vent, mounted my rear infinitybox powercell, and did some general cleanup.

ill get some pics rolling in as i start back on the project.

heres where Im at:

Thu May 06, 2021 5:21 pm

I finally installed the lever for the vanistan fresh air vent. Looking good. Ill end up clipping the lever part on a U bolt somewhere on the dash when i get there.

next i did some of this fake soundproofing up front so i could feel better about my life

Lastly, since the weather is FINALLY warm, I did a bunch of prep work and cleaning on the battery box area. Plan here is to put some fiberglass down, and then drill out drainage holes. There was some rot that I cut out (small bits) and didnt want to weld a whole new pan in, since the metal was good most places. Someone stop me if im insane for adding fiberglass- dunno, seems like a good idea.
Ill probably finish it off with either 3m rubberized undercoat that ive got leftover from the underside or some fake soundproofing stuff.

Tue May 11, 2021 11:29 am

Started laying down the initial wiring for the battery box and the infinity box stuff.

rear drivers side behind the brake light:

passenger seat box (all fiberglassed and nice:

passenger dash above glovebox:

Tue May 11, 2021 6:50 pm

nice seeing progress again! Keep the momentum going 8)

Tue May 11, 2021 8:14 pm

My mind was blown when I went to the Infinity Box site. Lots of really cool possibilities with that setup.

Mon May 17, 2021 12:28 pm

Zeitgeist 13 wrote: My mind was blown when I went to the Infinity Box site. Lots of really cool possibilities with that setup.

yeah, should be fun

Wed May 19, 2021 8:12 am

Took the single wiring run that goes front to back and did some prepping on it.

wrapped the 8ga infinibox power feed wires in a protective loom, and then wrapped that into a fiberglass high temp loom from del city electrical.

Making good progress here on the details of the electrical.

some pics:

Sun May 23, 2021 4:10 pm

Due to the different position of the Aircooled from the WBX trans, I had to cut my firewall and relocate the N75 sensor down on a different location on the firewall. I bought new silicone 8mm hoses to accommodate this:

Secondly, I was a little concerned with the ~18-22awg wires that came with the boxeer kit for the fuel pump and water pump,

Since I already rewiring everything, I decided to rebuild the connectors with 14awg. Greg assured me that max draw was around ~4amps. This 14awg gives me the headroom that I need.