my pan shortening adventure, and slow build

[rodjr]

Been a while since my last update, i have been consumed with building the engine. Long block is done and i think it turned out very nice. Specs:

New case. Hoover mods.
stock non c/w crank, offset ground 69.5mm(for a true 1600cc), 8 doweled.
Balanced with lightened flywheel and had DPR pin the Sachs pressure plate.
stock vw rods, straightened, rebuilt and lightened to 545 grams by Modok.
Web 163 cam advanced 2 degrees, Udo becker tool steel lifters, ACN pushrods.
Mahle 85.5 pistons and cyl's, lightweight tool steel wristpins, re-hone and balance by Modok.
.040" deck, 9.4:1 compression.
Mexico 043 heads, 36.5x32 ss valves, scat singles shimmed, Ti retainers, 42 cc chambers. porting and the rest of the work on the heads by Modok who took them to the next level...130+ [email protected] lift on intakes @25" all with a TINY 52cc intake port.
CB 1.1:1 rockers with TP tool steel adjusters, solid shafts.
CB filter pump with heat shield by me.
Csp 40mm manifolds matched by Modok.
nos weber 36 idf's with custom 31mm vents by Modok.
German 009 from tasb, re-curved by me with direction from Alstrup, 5800rpm rotor.
The whole engine build was inspired by Alstrups 110 hp 1600 combo.
Here she is so far:

A bit of work on the chssis as well, brake lines are done, pedal cluster restored and installed, new custom clutch cable from California push pull and new made in USA billet shifter from Mastershift.

[joescoolcustoms]

That all looks really nice!
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Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

[rodjr]

finally!
Engine is in, soon we will find out if my 36 IDF's are going to fit without changing a bunch of stuff.

At this point i have a question for anyone willing to grab a tape measure and check for me. What is a reasonable spacing between the stop on the back of the clutch pedal and the firewall/front bulkhead or whatever you want to call it? I have no idea, and want to get a baseline so i don't push the pressure plate past center.

Ride height guesstimate is working ok so far as well, pan sits 1" higher in the rear with the engine in and i was shooting for 1/2"-3/4" higher when finished, i think it will be close.

[rodjr]

Can anybody give me an idea of the distance between the stop on your clutch pedal and the firewall? Would really like some idea, already turned my pressure plate inside out once and there is a fine line where it goes over center. It would be good to know i am safe at least up to X amount of travel, i really don't want to pull the engine again to put my pressure plate right side out.

[cdnltded]

[rodjr]

Yes i understand this completely, however it is very easy to depress the pedal to the point that the fingers on the pressure plate go past center and fold inward. they do not return to the original position unless you pull the clutch and pop them back out. The stop on the pedal prevents this, but i do not know where to put the stop unless i slowly creep up on the pedal till the pp overextends and then make a stop just before that point. Unfortunately i will have to pull the clutch again to do this because the pp will be stuck over extended again.

[joescoolcustoms]

I think you have a bad pressure plate. The only ones I have heard of sticking compressed have been worn.

As a band aid, you can slowly back off the wing nut until you have about 2 inches after release of the clutch disc until you hit the froward firewall.

I personally never fully depress the pedal. I only press it about 3 inches just to release the disc, then shift and come back up.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

[rodjr]

Pressure plate is brand new Sachs, with new Daikin disc. It wasn't just stuck compressed, it went full over center till the fingers were stuck facing the disc. I am certain any pp would do this when the pedal can travel as far as mine can without a stop. I have to believe vw put a stop on the back of my pedal for good reason. I am building this car to absolutely wring it's neck and will give all 3 pedals a chance to punch a hole in the floor more than once, so i really would like a stop
I suppose i will just push it all the way though again and mark where it pops past center, set my stop a half inch or so before that point. then I get to pull the darn motor again, but that should be the last time.

[cdnltded]

i totally understand your troubles.
now just throwing this out there.
could your new pressure plate be defective. i am a mechanic by trade and sometimes new parts are assembled wrong or with out parts.
i once had a new tierod come with no threads to thread into the adjusting sleeve.
just because its new does not mean its right.

[57BLITZ]

[rodjr]

[rodjr]

On another note...
I found a place that would make custom decals with basically any size and design you can imagine, so i had them make something a bit more unique than the stupid green decals that were on my center caps.

[57BLITZ]

[rodjr]

[SBD]

Are those lower rear air deflector tins backwards and on the wrong sides?
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"Just $99 down and $64 a month for 36 months buys you a brand new Volkswagen Beetle!"

[rodjr]

Yes, they are. I didn't like how they looked sort of "unfinished" with the sharp formed edges facing out, so i tried flipping them to see if i could modify them to work that way which would look better. Ultimately though it is probably not worth the effort (and i would have to have them powder coated again after i cut and welded them) and i will probably just swap them back.

[rodjr]

After a long dry spell i actually had all day today to get back after it.
Finally finished up all the fiberglass work i had to do to clear the irs, then shot some raptor on the whole underside and a select portion of the top side.

[JaredJ]

[rodjr]

I don't have the info in front of me but off the top of my head i remember Zazzle and Stickerbeat both would do custom stickers (can't remember which i used). You could choose from their art designs or upload your own and get them sized and finished the way you want them.

[57BLITZ]

The 'glass repair turned out great!
And the Rapter looks nice . . . . keep up the good work!
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Jesucristo es mi Señor y Salvador!