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notchboy Samba Member
Joined: April 27, 2002 Posts: 22457 Location: Escondido CA
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Posted: Wed Sep 11, 2013 10:34 am Post subject: |
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Awesome work brother!
Im happy to know someone that will help me with my conversion when and if that day comes.
Keep up the work and hurry up! This shits taking like what 3 years now? More? _________________
t3kg wrote: |
OK, this thread is over. You win. |
Jason "notchboy" Weigel
1964 1500 S
1964 T34 S Convertible
1977 Westfalia Camper pop-top |
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Sloride Samba Member
Joined: February 09, 2002 Posts: 926
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Wed Sep 11, 2013 2:29 pm Post subject: |
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notchboy wrote: |
Awesome work brother!
Im happy to know someone that will help me with my conversion when and if that day comes.
Keep up the work and hurry up! This shits taking like what 3 years now? More? |
naw not that long... maybe 2 years? shit. Maybe it is coming up on 3 years now...
mostly its been sitting cause I was finishing out my degree. Now I'm out of school and still unemployed so, lots of time for the bus! Plus I have to move at the end of the month, so the car has to at least be driveable by then... _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
TOOB Member #3
I make D-jet FI connectors |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Wed Sep 11, 2013 3:52 pm Post subject: |
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another update
got my fuel return elbow back!
I need to shorten the ends so it'll fit right, but it's got the bend and the fuel return nipple for the EFI so I'm happy.
someone asked about rads:
here is the steel I'm making into a mounting bracket/ bypass air dam for the rads. There will be a twin/mirror on the other side.
the rad, 1 of 2 (the other will be mounted similarly on the other side) it's a single pass scirocco/ VW mk1 radiator. I wanted to do all aluminum dual pass, but the thickness and weight wasn't going to work in the confined space.
stock subie fan
I have to rig up a mounting system for these. or maybe find some mk1 vw fan shrouds. _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
TOOB Member #3
I make D-jet FI connectors |
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Fodder Samba Member
Joined: September 08, 2013 Posts: 65 Location: Oregon
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Posted: Wed Sep 11, 2013 6:14 pm Post subject: |
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Very inspiring!
Sorry if I missed it - have you decided on what starter to use with the KEP adapter? |
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Lionhart94010 Samba Member
Joined: January 04, 2005 Posts: 1417 Location: SF Bay Area / Silicon Valley / So Cal
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Posted: Wed Sep 11, 2013 6:40 pm Post subject: |
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With a twin rad on the other side it looks like you will have plenty of cooling :0)
Someday I may want to have a Subie option, I saw a couple on YouTube they seem to accelerated extremely well… _________________ Current VWs 71 T2 Westy SO-72/6(Miami), 71 Crew Cab, 2015 GSW TDI
Other owned VW’s 59, 68 1500s, 69 & 71 Bug’s; 72 & 73 S-Bug’s; 67 Westy, 67 Deluxe, Other 71 DC, 72 KG GT that now lives in Australia, 12 JSW TDI, 2015 GSW TDI, 2023 Tiguan
VW technical information sights
thesamba - www.ratwell.com - www.shoptalkforums.com/ - www.vw-resource.com - http://www.type2.com/
http://bobhooversblog.blogspot.com/ - www.aircooled.net/gnrlsite/resource/articles.htm |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Wed Sep 11, 2013 11:06 pm Post subject: |
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Fodder wrote: |
Very inspiring!
Sorry if I missed it - have you decided on what starter to use with the KEP adapter? |
right now the stock one is in there, and I was going to try using it before I went out and bought a heavy duty one. Some people have gotten away with using the stocker. _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
TOOB Member #3
I make D-jet FI connectors |
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Nepenthe88 Samba Member
Joined: September 03, 2010 Posts: 1320 Location: Colorado
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Posted: Thu Sep 12, 2013 7:57 am Post subject: |
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JSMskater wrote: |
stock subie fan
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Yes! This!!
This is definitely the way to go about doing a Subee transplant in a bay. It's a clean elegant solution and one that's proven to work in the hot HOT Aussie summers. You rock. The only reason I plumbed my bus different was cause the PO hacked giant holes in each back side. Booo!! And trust me when I say those stock subee fans are PLENTY strong enough to pull air thru the stock fresh air vents. So long as no air can escape around the radiators you shouldn't have a cooling issue. Here's a quick video of the air-flow being generated by one stock subee fan on my bus:
Link
_________________ a Black & Blue Su-BUS-aroo
Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/ |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Thu Sep 12, 2013 8:23 am Post subject: |
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Nepenthe88 wrote: |
Yes! This!!
This is definitely the way to go about doing a Subee transplant in a bay. It's a clean elegant solution and one that's proven to work in the hot HOT Aussie summers. You rock. The only reason I plumbed my bus different was cause the PO hacked giant holes in each back side. Booo!! And trust me when I say those stock subee fans are PLENTY strong enough to pull air thru the stock fresh air vents. So long as no air can escape around the radiators you shouldn't have a cooling issue. Here's a quick video of the air-flow being generated by one stock subee fan on my bus:
Link
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awesome video! I have no doubt it will work -- lots of others have done it successfully. I wish I had access to a CFD program so I could build a computer model but alas, I don't have 5k to drop on engineering software for personal use.
btw, I owe a lot of my conversion to some of your postings/musings via the wiring -- you'll notice I borrowed your fuse block/relay board design. keeps everything neat, and I have an orange LED light for my CEL. I might actually have a few questions for you about the wiring once I'm all done putting it back in -- namely I have 3 wires I'm rather clueless as to where they go/what they are, and they're not mentioned in that big long EJ22 conversion thread on STF. _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
TOOB Member #3
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Nepenthe88 Samba Member
Joined: September 03, 2010 Posts: 1320 Location: Colorado
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Posted: Thu Sep 12, 2013 9:05 am Post subject: |
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JSMskater wrote: |
btw, I owe a lot of my conversion to some of your postings/musings via the wiring -- you'll notice I borrowed your fuse block/relay board design. keeps everything neat, and I have an orange LED light for my CEL. I might actually have a few questions for you about the wiring once I'm all done putting it back in -- namely I have 3 wires I'm rather clueless as to where they go/what they are, and they're not mentioned in that big long EJ22 conversion thread on STF. |
Oh, hey thanks! If you go to the "EJ22 in the flatback bug" thread link in my sig (which you've obviously already been to) I should have posted links to all the documents I used to do my wiring harness. Theoretically, the answer should be in there somewhere Either way, PM me or post whatever questions you have and i"ll do my best to answer them! I'll be watching.
Also... I'm gonna pull the engine that's currently in my bus (works off a three plug engine harness) and swap it for the engine I was working on in the Flatback thread (2 plug engine harness) in a few days/weeks. That said, I'll have a working three plug harness I have no use for pretty soon. If someone else is afraid of doing the wire harness work and wants it, PM me. I'm sure we can work something out. Granted, it's not the tidiest bit of electrical engineering as it was done by the guy who started my subee swap, but it works (I've been driving with it). Thanks for the Hijack _________________ a Black & Blue Su-BUS-aroo
Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/ |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Mon Sep 16, 2013 12:34 pm Post subject: |
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progress
the rad fan modified -- had to cut off the stock tabs and weld on longer ones. I plan to eventually shroud the exposed parts of the rad on the right, top, and bottom with ABS plastic I can form with my heat gun.
pardon my heinous welds -- I'm out of practice and the steel I was using for the tabs/extensions was considerably thicker than the fan shroud steel, so I had problems with blow-through and getting the right setting on the welder.
this is when it was just tacked in
fully mounted its still a little ugly, but with some paint and grinding it'll look damn near professional.
as you can see, it blocks air from escaping except through the rad. this is the key. There will be sealing foam around the edges to prevent air from leaking past where it meets the body.
profile to get an idea for thickness
mocked in the car, not attached. I will be using riv-nuts where the stock insulation rivets used to be, with a tab welded onto the rad bracket so I can pass a bolt through to mount it. There will also be a tab on the bottom where it meets the body.
it's at an angle here so it wouldn't fall over, but you get the idea.
this gap will be filled with some abs plastic and/or foam seal.
another overall shot
what I plan to do for the intake manifold clearance problem...
I'm having the "U" pipe made up as I type...
moving on to the fuel pump and lines today! more to come! _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
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tootype2crazy Samba Member
Joined: October 08, 2007 Posts: 1276 Location: St. Louis Missouri
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Posted: Mon Sep 16, 2013 12:58 pm Post subject: |
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JSMskater wrote: |
another update
got my fuel return elbow back!
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This is a great idea! It would also work nicely for someone who wants to turn a carburetted bay into an FI one instead of replacing the tank. Early bays already have a metal line so the mod would be simple. Nice job! _________________ air-cooled or nothing for me
1978 Sunroof Deluxe Bus (daily driver)
1978 Transporter (mom's, making into a camper)
1970 Single Cab 2.1 turbo/EFI 6 Rib, 78 front beam, vanagon backing plates on rear (project)
2001 GTI VR6 (wife's) |
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Nepenthe88 Samba Member
Joined: September 03, 2010 Posts: 1320 Location: Colorado
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Posted: Mon Sep 16, 2013 12:59 pm Post subject: |
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wow. that engine is CLEAN, and nicely uncluttered without all the rigamarole and wires attached. Must be nice to work on like that! _________________ a Black & Blue Su-BUS-aroo
Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/ |
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BumbleBus Samba Member
Joined: August 17, 2009 Posts: 483 Location: Montana
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Posted: Mon Sep 16, 2013 2:54 pm Post subject: |
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Sourced your u-pipe locally I assume? Exact specs would be nice for future converters who don't want to reverse the intake manifold. Thx.
_________________ '72 L11H Campmobile in various stages of disrepair. Just bumbling along... |
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surfinbusslover Samba Member
Joined: July 26, 2012 Posts: 110 Location: Norcross, Georgia
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Posted: Mon Sep 16, 2013 7:42 pm Post subject: |
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man... THIS IS AWESOME! Im sitting down and watching this thread! Keep it up man, your the man! |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Thu Sep 19, 2013 8:35 am Post subject: |
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update!
so day before yesterday, I tried to install my fuel tank filler neck elbow replacement. I discovered that the alignment isn't perfect, but close enough to work without issues. Just wish I could kink the tip a tad. Anyways, I fought for 4 hours trying to get this thing in, and failed. I discovered what the problem was:
some bozo, probably the same bozo who cut the hole in my rear deck to get access to the gas gauge sender, replaced the filler neck hose with one that is 2" diameter. the pipe is 2.25". While at the time the rubber might have been soft enough to stretch, the hacked out straight sections I was using were NOT. So it wasn't sliding on the hard tubes in any appreciable way other than banging on it with a ring and a mallet.
SO I went to NAPA after discovering with my calipers the erroneous hose diameter, and got the correct 2.25" filler neck hose....
I was done in 20 min.
with new hoses:
old on left, new on the right.
installed.
you'll notice theres a slight kink- I ended up using my manly muscles to push these into a better alignment after I took the photos, but even so the misalignment isn't terrible. Not enough to cause leaks, and I used extra long hose length so it would seat perpendicular to the surface of the pipes, the "bend" in it is taken up by the flex in the rubber. we're good to go
sorry the photo is blurry, it was dark by the time I got to finishing this:
that, is a rivnut or rivet nut. Basically a rivet that has a threaded inner hole. I was able to re-use the existing insulation holes with these rivnuts, so I can re-install insulation and the radiator brackets with removable screws. I plan to use a few more, since they're rather small/wimpy screws. I could go larger on the rivnuts, but they get harder to install with a hand riveter the bigger you go and I'm almost out of funds for new tools. _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
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vwnutt6969 Samba Member
Joined: November 10, 2006 Posts: 79 Location: Florida
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Posted: Thu Sep 19, 2013 11:17 am Post subject: |
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Awesome job!
I'm getting my ducks in order to do the same to my 71 westy.
Only issue I'm having is, who makes the engine mount for this swap?
I have searched and searched and read but it seems to be the one thing no one talks about.
Could you post a photo of the mustache bar adapted to the EJ22?
Thanks! _________________ www.dubsontheboards.com |
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JSMskater Samba Grease Gorilla
Joined: February 01, 2006 Posts: 5362 Location: Murrieta California
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Posted: Sun Sep 22, 2013 9:10 pm Post subject: |
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phew. another update!!
radiator frame drivers side, final fitting before I weld it all up legit.
you can see here how it mounts -- tabs, with bolt head screws into the rivnuts. it is a TIGHT squeeze in there to get em in, but it is not difficult and can be done quickly. holds it tight too. the bottom has a bracket that follows the curve of the body, and is supported by a pair of studs.
this is how you mount the rad:
already attached to the frame/bracket with screws/washers from the other side, you swing this into place and it's supported from underneath by the studs and lower curved bracket. this way, you can easily install the upper bolts while still having some wiggle to get them in straight and without binding.
largest gap, this will be filled with a panel of plastic or foam seal.
upper bolts
the clearance in the back near the firewall -- pics tomorrow of it all fitting together but trust me it all fits!
with the rad mounted. this one is larger than the other, and the subaru had these asymetrical size fans. why? I don't know. But I'm repurposing what I have for now, but down the line I'll get the smaller from a junk yard and mount that instead for a cleaner look and better fit.
(dont mind the missing screw in the corner, I was just mocking it up)
annnd now the other side
same process for installation as the other side. mount rad to frame/bracket, swing into place, and bolt up. I haven't made the tabs for the top yet in these shots, but I'll do em up tomorrow.
fan for that side isn't done yet, but this is what it'll look like, but with the modified tabs and some extensions to the other side like the first rad fan.
(1st fan for reference:)
believe it or not (since it's still stained as hell) I scrubbed for over an hour with a blue pan sponge to get the engine bay clean. I think I may shoot it in black undercoat or something down the line. I didn't bother with the areas that will be hidden, just the engine bay aft of the firewall.
so, this part is ridiculously expensive (250!) but it did take time to make and I needed it fast so I can't really b*tch too much. this was the first attempt by the shop I contracted to make the throttle reverser:
and it was obviously a tad too tall.
so....
we fixed it.
with the engine lid shut (don't mind the disintegrating plastic)
sooo I'm exhausted but I have to keep pounding away at this. tomorrow I should have the engine hanger bar sorted out, and maybe get around to plumbing up the cooling and fuel systems. BTW the intake pipe is fully welded cleaned up and finished now, just haven't shot any pictures.
more to come! _________________ 71 Squareback-FI -- 73 Bay (subaru powered)
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notchboy Samba Member
Joined: April 27, 2002 Posts: 22457 Location: Escondido CA
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guanella74 Samba Member
Joined: March 13, 2009 Posts: 520 Location: Boulder, CO
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Posted: Mon Sep 23, 2013 2:25 pm Post subject: |
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Yeah! Keep this going! Inspired over here! _________________ - Travis
1974 Westy CampMobile - the OG!
1979 Transporter
1979 Transporter
1977 Transporter
1974 Transporter
1973 Transporter
1971 Westy |
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