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Jan 11, 2018 21:53:10 GMT
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This is my Fugitive Sandrail, a VW based kit from the 80's. All about them is here fugitives.co.uk/ Mine is a 1600 Bought it as a non runner late 2016. Replaced, fixed and upgraded a bunch of stuff and put it on the road (for the first time ever!) mid 2017. Decided to do an IRS conversion so bought the back end of a Porsche 944 S2, CVs, Axles and a handbrake set up. Also acquired a 002 VW Bus gearbox Before Porsche AS2 I made a jig, then chopped the torsion bar tube up so I could re use the brackets - to use the after market brackets and bushings was going to be £125 in extra parts of a lower quality! Welded these on reusing cut off bits of the tube to make spacers between the larger Porsche tube and the beetle one. They wrap round about 250 degs. then the spacers lock them in place. Not wanting to shell out hundreds for Porsche brakes I bought Golf Mk4 150/180hp Calipers (for 288mm discs). Then de-rusted and painted them. Sprang for a new set of Porsche discs ( which are 299mm x 24mm), and with a tiny bit of alloy removal they fit and work just fine. After The exhausts are a couple of 1300 Hayabusa bike cans
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Jan 11, 2018 22:09:33 GMT
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Drove that for a few miles then decided at xmas 17/18 it needed a better engine - I just happen to have a 139HP 1.8VVT engine from a MK2.5 MX5 - that and a few other bits is all that is left after I bought and stripped one for a kit car project, then decided not to do it! The engine weight is about the same and I worked out an interesting way of joining them by basically cutting the MX5 gearbox in half and joining it to the 002 without it's bell housing. (the bearing here sits in the housing but too cold to get it in) Going to cannibalise some splines off the MX5 drive and have them welded to the output shaft (above) and input shaft of the VW. Joining the two bits of Frankenbox with a big Ali plate - That's the theory today anyway. Meanwhile mocking up the exhaust and engine mounting So that's where it is today. Will post progress assuming someone is interested !
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Last Edit: Jan 11, 2018 22:11:27 GMT by wightfug
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lightyearman
Part of things
GYJDM - Grimsby based Japanese car club - Find us on Facebook
Posts: 639
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Jan 11, 2018 22:09:50 GMT
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I'd love a sandrail if I lived anywhere I could get some use out of one!Neat work on the IRS there. do you get more travel out of having that setup?
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'89 Honda CRX siR Glassroof Flint black fully restored track beasty '90 Nissan S13 Pignose - pass the mig wire '86 Mini - matt orange, 13" Wellers, Project 2018 '97 LDV Convoy home built camper/tramper van '04 Saab 9-5 Aero HOT. Anyone want it? '91 Honda VFR400 NC30 17,000 km from new '87 Honda XR80 4 stroke baby crosser '03 Mini Cooper S - honestly, they are fun... '15 VW T5.1 LWB daily brick
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Jan 11, 2018 22:14:15 GMT
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More theoretical travel as the S2 CVs are good for 22degs vs 12 degs for the Beetle swing arm. I did not bother to maximise that as I literally did 2 miles in it before starting the engine swap.
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Jan 25, 2018 20:42:03 GMT
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Last Edit: Jan 26, 2018 0:21:48 GMT by wightfug
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Tacked up the first part of the engine cage:
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Hey mate, this kind of stuff goes well above my head but I really like reading about it. There are some clever cookies out there, you must be one of them.
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Last Edit: Jan 29, 2018 6:08:35 GMT by rblote
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Jan 30, 2018 22:11:17 GMT
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Hmm.. actually I make it up as I go along - but nice of you to say so anyway!
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Jan 31, 2018 17:59:44 GMT
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Those crazy Germans have put the gearbox output shaft offset to one side by 15mm - so the whole engine will be very slightly not central Oh Joy...
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Jan 31, 2018 19:48:45 GMT
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Doing something slightly similar with a 3.7 Audi in the back of an Audi a3. My gearbox is near 30mm off center.
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80's Fugitive Sandrailjohnthesparky
@johnthesparky
Club Retro Rides Member 6
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Jan 31, 2018 20:06:00 GMT
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Those crazy Germans have put the gearbox output shaft offset to one side by 15mm - so the whole engine will be very slightly not central Oh Joy... Is the shaft offcentred in the bellhousing?
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Yes and no! The shaft coming out of the box is offset 15mm l/r and about 60mm up. But the bellhousing (that is separate to the box) offsets the engine so it is in the centre. (ignore red line in pic) I am not using the bell housing to cut down the length of the connection.
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80's Fugitive Sandrailjohnthesparky
@johnthesparky
Club Retro Rides Member 6
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Ah, I see. I guess I knew it would be up because it has to go over the diff, but couldn’t picture the side to side offset (and we bolted the engine on at the weekend so couldn’t look at ours)
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Ah, I see. I guess I knew it would be up because it has to go over the diff, but couldn’t picture the side to side offset (and we bolted the engine on at the weekend so couldn’t look at ours) John, you wouldn't have seen it on yours because you're still on a Beetle 'box but this is an 002 early Bay Window bus 'box. Not as strong as the 091, but much easier to get hold of, and there are various mount kits available for both, some to move the gearbox to one side (different length axles but central motor), the others keep the gearbox centred but have the engine offset. With the MX5 engine I'd go for the latter, but the former in a flat four engined Beetle.
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1968 Cal Look Beetle - 2007cc motor - 14.45@93mph in full street trim 1970-ish Karmann Beetle cabriolet - project soon to be re-started. 1986 Scirocco - big plans, one day!
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Yea at 15mm I'm not that bothered - didn't even notice when I mounted the beetle engine on it.
Makes designing the adapter plate more awkward than it already is and slightly complicates the engine mounts - but if it was easy everyone would be doing it!
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here s my ole one .waspurple what a difference a colour change makes
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Last Edit: Feb 3, 2018 15:02:50 GMT by shielsy68
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Back to the adapter plate, I used a cheap scanner and CAD to make a template for the laser cutters by overlaying the scanned images of the two parts. Getting it cut in 1mm steel to check it fits before the 23mm Ali needed to accommodate the diff stick out.
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Feb 28, 2018 15:50:28 GMT
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Now need to get MX5 shaft welded to VW shaft Spoken to two separate recommended motorsport engineering shops, one said "sure, do it all the time no problem", the other said "nope, fail, disaster, need a new shaft making for £££" - however shop 1 has not been heard of since... So as a backup plan if I can't find anyone to do it, I am investigating throwing away all my work so far and starting again and making a Franken clutch so I can just use the VW shaft. The VW clutch plate is 200mm and the 1.8L MX5 engine clutch is 215mm - consequently the MX5 flywheel and ring gear won't fit in the VW bell housing. However, I have discovered it is a known mod to put the 200mm clutch off a 1.6L on the 1.8L engine as a poor man's lightened flywheel, so if that would fit in the bell housing, a VW plate looks like a standard item so I use that, spigot bearing is the same ID, and if I can get the throw out bearing to work.. easy!
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