engine refresh 1968cc, with heat

[W1K1]

i'll try to remember to check the temps, the heat is still sneaking into the cabin... and its +25C outside right now.
I was sitting at the lights on my way home from work last night, and I notice warm air coming from the defroster vent
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

been changing the jetting and getting nowhere , then I thought Maybe the airbox is running out of air

so after running a few with the airbox on:

I had leaned out the mains 132, and idles 56 but the readings were worse than the previous ones i posted. I'm at 10.6-11.4 AFR at wide open throttle

10.9-11.2 AFR at wide open throttle

and 50 mph lean cruise is 13.5-14.7 AFR

So back to the garage and pull out the skinny little type 3 filters that come with the CB linkage and take it for a boot.
First off ...hearing the intake noise from the dells is great!

4th gear on the highway, buried the speedo, and didn't even get close to the rev limiter

cruising down the highway, it still went a little rich when we got on the gas

3rd gear WOT on the highway 11.6-12.6 AFR

and the map for the CB black box, Alstrup was giving me some pointers on the map layout, it seems to like it. the engine never gets to 100% on the map, it idles around 65, and at WOT it only goes to 90, but we'll see if the airbox has anything to do with that

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Alstrup]

Gotten the new venturies in yet?
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https://www.thesamba.com/vw/forum/viewtopic.php?t=435993

[W1K1]

still waiting on them

They said they were shipping on Friday the 14th, then Monday, still no answer back from my e-mail yesterday. I'll call at lunch to see what's going on.
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

shipped fedex , they are supposed to be here tomorrow, so that's good.
While I'm in there swapping them out, what should the floats be at?
I'm currently set a 5.5mm
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

new 30/34 grooved venturi from Berg for the 45 dells

30/34 berg grooved venturi
57 idle
130 main
200 air
1/2 bung on vintage speed muffler

lean and popping on the 57 idles at light pedal cruise, i'll go to the 60's next.

the mains are looking good at WOT, and it sounds right.

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Cptn. Calzone]

What airfilter did you settle on?The little ones or the stock box and a scoop??
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71 westfalia
67 912 Porsche Quintilla
67 Single Cab aka my work horse

[W1K1]

I'm still messing with the jetting , I don't think the airbox is going to have the capacity for the 45's , so I'm running the short ones for now. Once I get the jetting sorted I'll swap in the airbox and see if it falls on it face.
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Cptn. Calzone]

I was wondering about that because I wish to run a good air filter the little shorty's I don't like I was going to take the stock air Box and modify it like you did and definitely cut his scoop to get more air back into their
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71 westfalia
67 912 Porsche Quintilla
67 Single Cab aka my work horse

[Jason37]

Now that the nights are getting a little cooler, hows the heat?

[W1K1]

I had to plug the holes, the flaps on the heat exchangers sometimes close half cocked and were cooking me out. I'll unplug them one one of these days
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

last winter I started looking over the intake system and being able to adapt it to the 45 dells.

the restriction being the small intake on both sides. I had a 2.5 diameter hose feeding from the front, which is 4.90 sq inches, but it was coming in through a hole that was only 1"x 4", only 4 sq inches

so I chopped off the tube where it passes through the tin, and made a new end for the hose with a bigger 3" hose (7.07 sq inches) to feed it and try to make a a bigger/better connection to the filter housing

stuff some blue foam in, and start carving, and fitting it in the engine bay to connect to the housing.

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

the first mock up was a quick fiberglass connection.
It was off on the connection angle, but close enough because I want a better connection that a rubber sleeve that you couldn't reach down the back anyways.

got in and enlarged the hole from the inside, so no more restriction, then cut the
connection in half to fix the angles and add a flange to the connection

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

expanded the flange on the connection, so now I can seal it with some thin foam. and the filter housing drops right down into it. Which means a whole lot less struggling to get it in and connected.

I used a bunch of modelling clay to get the shapes and connections right, there's no way to get behind it when the two pieces are together so the clay gives a nice line to work with

expanded the back hose to a 3" connection as well
It's all pretty fugly until it gets sanded and smoothed out, but until it all fits and flows, it's just a work in progress

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

finally zeroed in on a pretty good jetting combo
it woke things up, and it doesn't feel like a soggy bogger

strangely enough it is a much leaner combo on the 180 airs, that running the 200 airs was.

next is testing the mods I did on the air box to see if it flows enough air

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Jason37]

I really like the stick to it attitude, most would not have even started and even less would have continued down the path.

[W1K1]

new sealing foam for the air box

3 inch hoses on both sides feeding the air box

all back together, the paint is fugly, but I want to make sure it works before we worry about appearances

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

so the good news is that it works, but it is showing richer at idle when the car isn't moving.
I'm at 12.5 -13 AFR , which isn't a big deal, but it was idling at 14ish before.

I didn't cut the stock outlet on the body for the 3" hose so that is a restriction, but it seems to be fine on the AFR in all but the sitting idle.

there was 4 of us in the car on the weekend, and it was easy to carry on a conversation, but I can't hear the dells whistling anymore
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[W1K1]

so after driving it for a while with the airbox on, I've dropped both the idle and main a smidge and it runs/sounds better.
And the AFR is where I think it should be, at cruise light throttle 15-16 AFR, at WOT it's 12.2-13.3 AFR

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[DevonNotch]

[That's a work of art mate!