Manx KickOut Build Project

[SoCal67Volks]

[hillmotorsports]

You obviously have much more VW engine experience than me so can you please explain the logic or compare the Thing shroud and type 4 cooler vs a separate remote cooler and fan?
Since you seem concerned about clearance with your body was wondering if the change was worthwhile....and of how much value vs other routes.
Feel free to chime in with your thoughts as well Joe!
Trying to educate myself without making rookie mistakes in logic...
Thanks

Paul
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Rosemarie and Paul Hill
Morrisburg, Ontario

(With way more projects than spare time!)

[SoCal67Volks]

The factory units are very well engineered with special consideration to vane size, shape and placement to assure proper airflow to across of the critical areas. Until I found this fan shroud, I haven't found an aftermarket fan shroud that can match the cooling performance of the OEM units.

In addition to air flow, our little flat four engines also rely on oil to keep them cool. The type 4 oil coolers have close to 20% more surface area that I hope will offset the lessor heat transfer of the aluminum case.

As far as external oil coolers & clearance issues, I'm trying to keep all of the external dangly bits (with exception of the full flow oil filter) to a minimum. My buggies also serve double duty as my engine break-in stand / on road dyno for my sedan engines. It's so much easier to break in, diagnose or adjust valves for my new sedan engines in the Manx before wrapping a car around them. Keeping the engine simple, compact and easy to swap is my personal preference.

My favorite comment from the TV show "Chasing Classic Cars" was from the older technician while working on a Porsche 356 was: "German Cars don't like clever things"
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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[SoCal67Volks]

After two weeks of assembling and disassembling (6 times at last count), I'm done with this engine.
It was a very happy day taking the engine off of the stand.

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[SoCal67Volks]

The engine is in at last!
Setting up the throttle cable was a breeze without the body. The throttle stop of the pedal and carbs are now matched. Fuel lines are next. I'm going to run the engine and break it in before mounting the body.

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[clonebug]

It's crunch time.......Are you planning on Big Bear this year????

Looking really nice!!!!!!
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[SoCal67Volks]

Thank you!
Yes, I'm driving this thing to Big Bear in 10 days.

(....and yes, I'm nervous!)
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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[hillmotorsports]

We're cheering you on Jim!
That thing is looking awesome, is a great testament to your anal retentiveness
Sorry we can't be there to assist...."many hands make light work"...but could never figure what hands had to do with electricity!

Paul
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Rosemarie and Paul Hill
Morrisburg, Ontario

(With way more projects than spare time!)

[SoCal67Volks]

The chassis is complete and one last look before it's covered up.

_________________
1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[vwjetboat]

engine all broke in ? great build man..

[SoCal67Volks]

[SoCal67Volks]

The body was mounted (at long last) back onto the new chassis. From the very beginning I'd planned on building this Manx as a sports car. After the body was mounted I finally got to see the stance I've wanted since day one.

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[SoCal67Volks]

A "BEFORE" Pic prior to the new stance (& new engine):

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[hillmotorsports]

Looks pretty sweet Jim!
Sorry we can't be at Big Bear to watch you and Shelley in your debut.
I'm sure Bruce will be proud to sign this as another one of his offspring!
Pictures of the event please......
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Rosemarie and Paul Hill
Morrisburg, Ontario

(With way more projects than spare time!)

[hillmotorsports]

More detail curiosity questions.....
I see your remote oil filter mounted in front of the the left side of the motor.
I presume the intent was less chance of knocking it off than when mounted low at the rear?
What type of mount did you use?
Routing and type of oil lines?
Your picture chronology skipped those details....😊

PS....seems my old eyes are paying tricks. I now notice the filter at the rear in your last photo. Reason for change? Obviously you did a rethink......

Paul
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Rosemarie and Paul Hill
Morrisburg, Ontario

(With way more projects than spare time!)

[SoCal67Volks]

While I was fitting the cooling tins, I realized that the lower tins that mount to the engine case also needed the heater box (that I'm not using) for their outer mounting points as well as keep the air flowing the way Wolfsburg intended.

I used some sheet metal to form my own air deflectors. They seemed a natural for doing double duty as a place to secure my full flow lines. The filter mount is a simple aluminum hanger we've been using on our sedans for 30 years http://socalautoparts.com/shop/oil-system/filters-...-aluminum/

The plumbing is standard aircraft AN -6 and I went with the cloth braided line that's rated at 3X the pressure & temps that I'll ever see and it's much easier to cut and assemble than the braided stainless lines (& fewer band-aides!). The oil filter is the cheapest money can buy. I go thru 2 of them before the car leaves the garage. The Framm HP3 that I'll drive with is half the size of the break-in filters and will be level with the bottom of the engine case. Moving the filter forward just cleans everything up / gets rid of the clutter.

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[SoCal67Volks]

It's now the day before the 2017 Big Bear Bash, I'm out of time and never had a chance to break in the rings. I usually flat tow but the new chassis mounts to the front beam at the same spot my tow bar used. My wife couldn't make the trip this year so she, my truck and tools stayed home. I took a quick shower, a leap of faith and (my AAA Card) took off for my solo 150 mile trip from sea level to Big Bear Lake at 6752 feet elevation.

From the beginning I had a lean condition in 1st & 2nd gear but the first third of the trip was stop & go traffic that gave me plenty of time to figure different shift points and how to just "tickle" the accelerator pump for an extra drop of fuel to keep the snapping and popping at bay. Once past the traffic I could open her up. This thing pulls like a freight train and at 70 mph is smooth as silk (all the balancing paid off!). The round trip totaled 350 miles, averaged 24 mpg and didn't use a single drop of oil.

Engine: Very Happy.

During the climb up the mountain the 4000, 5000 and 6000 foot elevation markers seemed to fade away at one minute intervals. I was accelerating past 50 mph on a straight stretch and looking at the speedometer when a 10mph hairpin to the right caught me off guard. I grabbed a gear and inititated my turn but got caught a small rise in the asphalt at the apex. I had daylight under all four wheels but she flew flat, settled softly and the torque pulled me up the hill without any drama whatsoever. Although my heart rate never changed or skipped a beat, it took over ten minutes to get the silly grin off my face.

Chassis: Extreemly Happy!

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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera

[Manx102]

Congratulations on your very nicely done Kick-Out and a wonderful first trip with your buggy.
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"The simplest of outdoor adventures - the most treasured memories." - Bruce Meyers
54 years of "outdoor adventures" and "treasured memories" with our Manx in my gallery.

[clonebug]

Nice work!!!! ....No.....Excellent Work!!!!!!!!!!!

That buggy was a beauty last year and it looks top notch again this year.

Too bad all that chassis work is mostly covered......
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[SoCal67Volks]

Thanks, Guys!

This was a fun adventure. The last week was grueling, I was sick as a dog but the Big Bear Bash was on the horizon and I had to press on. After getting it home I found both inboard CV boots leaking grease. I must've pinched them during assembly.

Catching up on chores, I haven't touched the car in over 24 hours but each time I go into the garage, I get a big dopey smile on my face!

Man, this car is fun to drive!
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1967 Type 1 Sunroof
Meyers Manx Kickout
Meyers Manx SR2

"Making a car look complicated is easy, making it look simple is hard." John Buttera