Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts New!  See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
1981 (@wileythewesty) TDI conversion, from ground up
Page: Previous  1, 2, 3, 4  Next
Forum Index -> Vanagon Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
Zeitgeist 13
Samba Member


Joined: March 05, 2009
Posts: 11003
Location: Port Manteau
Zeitgeist 13 is offline 

PostPosted: Sat Nov 21, 2020 11:35 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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

Image may have been reduced in size. Click image to view fullscreen.

_________________
Casey--
Volkswagens powered by Volkswagen
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender VR6 -->2.5 TDI Syncro?
Oly Bulli
'87 300TD OM606 7mm Myna pump and HX30
Back to top
View user's profile Send private message Gallery Classifieds Feedback
MarkWard
Samba Member


Joined: February 09, 2005
Posts: 14504
Location: Palm Beach County, Florida
MarkWard is offline 

PostPosted: Sun Nov 22, 2020 8:54 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.
_________________
1982 Vanagon Camper with ALH TDI.
1990 Vanagon Camper Syncro.
In Car https://youtu.be/5hbfdUJR88Q
Back to top
View user's profile Send private message Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Sun Nov 22, 2020 10:15 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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
Image may have been reduced in size. Click image to view fullscreen.


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

Image may have been reduced in size. Click image to view fullscreen.

_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
syncrogreg
Samba Member


Joined: November 08, 2009
Posts: 729
Location: USA (Nashville TN)
syncrogreg is offline 

PostPosted: Sun Nov 22, 2020 11:21 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.



Image may have been reduced in size. Click image to view fullscreen.


Greg
_________________
conversions: www.boxeer.com Common rail TDI and NOW PDK transmissions!!

travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Fri Nov 27, 2020 7:57 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


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.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Cut it out of some spare galvinized sheet metal, welded it back on- and now I have a proper modern sized mount.
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Fri Nov 27, 2020 3:23 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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


Image may have been reduced in size. Click image to view fullscreen.



I also did some test-fitting with the new, nice sound deadening (VB-TSM http://cascadeaudio.com/car_noise_control/vb_tsm.htm) 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.

Image may have been reduced in size. Click image to view fullscreen.
[/url]
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Tue Dec 01, 2020 5:36 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.


Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
4Gears4Tires
Samba Member


Joined: October 08, 2018
Posts: 1588
Location: MD
4Gears4Tires is offline 

PostPosted: Wed Dec 02, 2020 7:41 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

That's a neat engine lift.
_________________
'87 Syncro
Ferric Oxyhydroxide Superleggera Edition
Back to top
View user's profile Send private message Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Wed Dec 02, 2020 9:04 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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

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

_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Tue Dec 08, 2020 9:28 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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:


Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


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
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Wed Dec 09, 2020 11:37 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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:


Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
erste
Samba Member


Joined: March 29, 2013
Posts: 980
Location: San Francisco
erste is offline 

PostPosted: Wed Dec 09, 2020 11:48 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

Hell yeah! nice progress!

Why does the 091 Aircooled transaxle push things forward?
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Thu Dec 10, 2020 6:55 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
?Waldo?
Samba Member


Joined: February 22, 2006
Posts: 8736
Location: Where?
?Waldo? is offline 

PostPosted: Thu Dec 10, 2020 7:57 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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).
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Zeitgeist 13
Samba Member


Joined: March 05, 2009
Posts: 11003
Location: Port Manteau
Zeitgeist 13 is offline 

PostPosted: Thu Dec 10, 2020 8:20 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.

Image may have been reduced in size. Click image to view fullscreen.

_________________
Casey--
Volkswagens powered by Volkswagen
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender VR6 -->2.5 TDI Syncro?
Oly Bulli
'87 300TD OM606 7mm Myna pump and HX30
Back to top
View user's profile Send private message Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Thu Dec 10, 2020 9:57 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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.
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
?Waldo?
Samba Member


Joined: February 22, 2006
Posts: 8736
Location: Where?
?Waldo? is offline 

PostPosted: Thu Dec 10, 2020 10:00 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

You might need to lengthen one linkage rod. I don't think you'd need to do any other changes to the shifter/linkage.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Zeitgeist 13
Samba Member


Joined: March 05, 2009
Posts: 11003
Location: Port Manteau
Zeitgeist 13 is offline 

PostPosted: Thu Dec 10, 2020 11:45 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

I'm running a modified 091 rear shift rod mated to a stock 091/1 front section. Shifts are buttery smooth.
_________________
Casey--
Volkswagens powered by Volkswagen
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender VR6 -->2.5 TDI Syncro?
Oly Bulli
'87 300TD OM606 7mm Myna pump and HX30
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Vanagon Nut
Samba Member


Joined: February 08, 2008
Posts: 9454
Location: Sunshine Coast B.C.
Vanagon Nut is offline 

PostPosted: Thu Dec 10, 2020 2:28 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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

https://lh3.googleusercontent.com/pw/ACtC-3dtIwpR6...4-h1015-no

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

https://lh3.googleusercontent.com/pw/ACtC-3exB6oHP...4-h1015-no

Overall, I saw ~ 2.25" difference

https://lh3.googleusercontent.com/pw/ACtC-3elP75Tr...3-h1015-no

https://lh3.googleusercontent.com/pw/ACtC-3cFBfPoN...17-h516-no

Neil.
_________________
1981 Westy air cooled to 15ļ ABA swap: http://tinyurl.com/y9n4xob8

50ļ ABA Swap in to '88 Westy: http://tinyurl.com/yap5hpwt

Vanagon VAG GAS engine swap Google Group:
https://tinyurl.com/2f24rmh

VE7TBN
Back to top
View user's profile Send private message Gallery Classifieds Feedback
charleslabri
Samba Member


Joined: December 08, 2019
Posts: 335
Location: South Lake Tahoe
charleslabri is offline 

PostPosted: Thu Dec 10, 2020 2:58 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

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

that should be a sticky
_________________
-------------------------------------------------
An example of my slave labor in action:
https://www.instagram.com/wileythewesty/
Back to top
View user's profile Send private message Instagram Gallery Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Vanagon All times are Mountain Standard Time/Pacific Daylight Savings Time
Page: Previous  1, 2, 3, 4  Next
Page 3 of 4

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2020, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB