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I feel your pain with the gearboxes - I've got a superdiff and heavy duty sideplate to try to make an otherwise stock box last with 160bhp but they're both in cardboard boxes on a shelf. Took the axles off a '66 (supposed to be the strongest factory short ones) then stripped the diffs out of two later boxes. One had the strong 15-tooth side gears, but one had shattered around the side and eaten the fulcrum - not as bad as yours though. The other had the weaker 17-tooth side gears but one of those had a crack up the side of it. Back to the '66 'box for the side gears from that! No idea what I'm doing with regards to setting side play and gear backlash!
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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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Just a thought Dave, while your car is in bits, is it worth welding in the IRS brackets for a later conversion to bus box?
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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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fad
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Posts: 1,781
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I nearly IRSd it but wanted to press on.
Confession time: I haven't set anything on mine, just left as is. Both boxes had two plastic gaskets both sides so just done that. Hoping for the best!
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fad
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Posts: 1,781
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Aug 31, 2017 17:50:48 GMT
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Well this is stoopid. I've been rebuilding for so long, they've put speed humps on the road to the unit.
Big ones.
I'm too low for speed humps. Especially big ones.
Doh.
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Aug 31, 2017 22:27:18 GMT
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Well this is stoopid. I've been rebuilding for so long, they've put speed humps on the road to the unit. Big ones. I'm too low for speed humps. Especially big ones. Doh. You just have to go a bit quicker! How much adjustment have you got? I'm guessing not enough (I thought this was going to be photos of you driving it!!)
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fad
Posted a lot
Posts: 1,781
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Hahaha sadly not pics of me driving it I'm afraid! Actually the adjustment is deceptive, I can go back to stock height with a couple of spanners and a trolley jack if I need to (though my shocks won't like it one bit!). The humps are those ones where there's one each side of the road and you are meant to straddle them... The worst kind for my Volksrod cos there's no way I can get over them!
Last night was spent making the spreader plates for the pan bolts (cos I'm cheap and I'll be damned if I am paying £2.50 each for them when I need 22 of the things and all they are, are large washers bent into a U shape). So bought a load of 3mm 50x50mm stainless roofing washers and bent them into U shapes. Cost me much much less! Found that I need to tweak the pan holes slightly on one side to get the body on, but I'm very close (about 2 or 3mm off, which isn't bad given the extend of the welding that has been done and the fact that I lost all my datum edges while cutting out the rot). Nothing interesting to take pics of though. Waiting for some gaskets and seals to show up so I can finish assembling the suspension at the rear. bolts arrived for the rear adjustable springplates though (yey!).
I should really add up the amount of money I have saved vs the amount of time it cost for all the trick bits I have made myself...
So, the adjustable springplates have taken me about two days total, and cost me nothing (could do it in a day if I pushed). There's a saving of about £160.
The beam. I repaired it myself and welded in my own adjusters which I scored as a freebie - no idea how much adjustable beams cost but I've spend a couple of days doing that.
Gearbox raise kit... I've not seen these for sale for AGES! Not 2.5" ones anyway. I should really make a few to sell...
I could be at this all day if I thought about it hard enough... Haha!
I'm really, really tempted by the 1800cc pistons VW Heritage have on offer right now... But... BUT... That would mean some machining would be required... Which is fine, I have access to a miller. But then... I'd also need to think about the fact that my engine already eats gearboxes, another 240cc of displacement will not help matters on that front! Plus... Well... Hmm... It's SO tempting... Grr...
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Last Edit: Sept 1, 2017 8:39:51 GMT by fad
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But MOAR POWERZ!!!!11!! I'm guessing you need to IRS it to get the stronger gearbox to take more power, and you've just made the bits for swingarm.... so probably not
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fad
Posted a lot
Posts: 1,781
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I can slap in a Rancho box, at £2k5+... But all that does is moves the weak spot to somewhere else (likely my frame horns).
Of course, if I keep the diff as the weak spot, I can pick up used gearboxes for as little as £50 if I look hard enough, though £100-£150 seems to be the usual rate... So, if I buy a rancho, brace the framehorns, fit race axles etc and spend, realistically, around £4k on bits... I can buy 40 or so gearboxes before I would have been better with a rancho... Assuming 1 gearbox a year, writing it off as a service item, with 10 for intermediate changes when I've been racing, that's still 30 years of motoring hahaha!
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Sept 1, 2017 10:03:31 GMT
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Easier to change the oil when they are out too
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A mate of mine with a 2165cc turbo motor used to get four 1/4mile runs out of a stock gearbox! Unfortunately you'd often have 4 qualifiers plus eliminations!
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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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fad
Posted a lot
Posts: 1,781
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So a little more progress... Mocked up the pedal cluster and found that things don't quite line up... So. Some more cutting, drilling, welding, and general faff means that it all now fits, so whipped it back out and wire wheeled the lot and it is now sitting in primer waiting to be painted (either red or black, not sure yet!). Clagged the brakes on and the seals etc (do NOT buy the cheap hub seal packs from VW Heritage. They don't fit. Not even close. Had to make my own gaskets and seals in the end). Then had to earn my keep, so hitched up the trailer to the warhorse and dropped off a Ghia body shell at the blasters. Stopped to get lunch on the way... Park like a complete douche level: EXPERT
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Sept 8, 2017 14:18:41 GMT
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"Park like a complete douche level: EXPERT" HA!....good one....lol undercarriage black cherry or maroon..... JP
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I know its spelled Norman Luxury Yacht, but its pronounced Throat Wobbler Mangrove!
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fad
Posted a lot
Posts: 1,781
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Sept 17, 2017 8:21:00 GMT
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Well, did a little more. Got the pedal cluster painted, steering column is out and in primer as is the steering gear (box, rods etc). Then we got the shell painted inside, and the wheel arches... Same paint as the chassis. Before: After: Before: After: Before: After: Starting to look tidy now, finally! She'll always be ratty but at least she's solid!
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fad
Posted a lot
Posts: 1,781
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Sept 17, 2017 8:23:45 GMT
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Plan is to fit a new dash (that one is knackered), and then I can seriously think about the interior. The biggest relief is getting paint up into the roof on the inside, so that all the seams from the chop don't rot out from the inside.
Plus, the paint being what it is, will give a little sound deadening too, always a bonus!
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Oct 27, 2017 12:14:17 GMT
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ON THE ROAD YET?
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96 E320 W210 Wafter - on 18" split Mono's - Sold :-( 10 Kia Ceed Sportwagon - Our new daily 03 Import Forester STi - Sold 98 W140 CL500 AMG - Brutal weekend bruiser! Sold :-( 99 E240 S210 Barge - Now sold 02 Accord 2.0SE - wife's old daily - gone in PX 88 P100 2.9efi Custom - Sold
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fad
Posted a lot
Posts: 1,781
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Nope not much progress at all really
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Nov 10, 2017 13:50:57 GMT
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B-|Thought it was an update!
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Nov 10, 2017 17:23:51 GMT
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What he said.... I settled down for an update too.... That’s 2 of us, so you should drop everything else so we have something to read
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fad
Posted a lot
Posts: 1,781
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Nov 10, 2017 18:32:45 GMT
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I will. There is an update of sorts... Had my engine tins blasted and primed. Likewise the inside of the doors and bonnet. Have also put some bodge on the door bottom of one door to get it part ways flat. Also been shooting paint on test cards. But there's no big thing to report nor am I closer to it being on the road, just lots of faffing about. No pics yet, sorry!
NO LONGER UPDATING THIS THREAD.
I've come to the conclusion that this forum just isn't for me, for various reasons that I won't get into because it would be fruitless. But I'm off, maybe you'll see Bad Juju on the dragstrip sometime.
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Last Edit: Jan 23, 2018 8:13:24 GMT by fad
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