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Old 05-18-2017, 07:21 PM   #201
Tfrasca
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Dude! Whoa!

BTW, you can buy different length cheapie steel velocity stacks from aftermarket aircooled VW catalog companies like CIP1 or JBugs. CB Performance sells really nice die cast aluminum ones too. But what you did is way more awesome!
Damn, I wish I'd seen CB Performance before... I needed aluminum stacks, so they could be welded in. Some of the CB ones look like they'd have worked. Oh well, at least I learned a new thing!
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Old 05-29-2017, 11:49 AM   #202
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So, I got all my manifold parts fit up yesterday, and brought it all to Noah's to have him tack it together. The good news: it fits in the car. Clears the booster by over an inch, doesn't hit the heater valve, and with some minor adjustments, it will definitely work.

I have to trim the front face of the plenum back 20mm to give me more room for throttle body/IC pipes. I'll also slightly re-do the upper radiator hose to help in that area.






When I was "designing" it, I got too concerned about clearance on the booster side, and the plenum ended up too close to the #1 injector plug. (Injectors mounted in Kjet holders, means the plugs have to face the manifold, not the head.) To remedy this, I ordered some phenolic spacers.



Here are the STS machining Kjet plugs that I drilled out for EFI injectors:

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Old 05-29-2017, 01:37 PM   #203
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You making an extra manifold for me? Wink wink.

Looks amazing!

Thanks,
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Old 05-29-2017, 04:53 PM   #204
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you make it look so clean! good job. what powergoals you shooting with that m41 gearbox?
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Old 05-29-2017, 04:57 PM   #205
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you make it look so clean! good job. what powergoals you shooting with that m41 gearbox?
Thanks! I do like a clean engine bay, so that's been a motivating factor.

I have no delusions that the M41 will hold up for long. I have an 8 psi wastegate actuator on it now, and I'm hoping to keep it at or below 200 hp until I can get around to the transmission. I didn't want to tackle the transmission and the rest of the engine stuff all at once, and this gives me some time to decide between T5 or Getrag 265.

Once the transmission is up to par, I'll crank up the boost and hope for ~250 hp/tq.
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Old 05-30-2017, 10:35 PM   #206
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Nice build! Done thought out and without being pretentious!

I'm also a big fan of these wheels, seems they fit better under a 122!

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Old 05-31-2017, 05:30 AM   #207
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damn , this is a really nice build!!
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Old 06-07-2017, 07:58 PM   #208
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Oh my god.

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Old 06-07-2017, 08:23 PM   #209
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Old 06-07-2017, 08:25 PM   #210
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Me too! I have a lot of observations and feelings about this car now, but all I can muster is "oh my god"...
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Old 06-07-2017, 08:31 PM   #211
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Sweet! Taking it to ipd?
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Old 06-07-2017, 09:16 PM   #212
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Oh my god.

congrats! would love to hear some driving impressions when you have recovered lol
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Old 06-07-2017, 09:28 PM   #213
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WHOA! Congrats! Looking forward to Canepa!
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Old 06-07-2017, 10:03 PM   #214
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Good to see you finished this, and great fab skills also!
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Old 06-07-2017, 11:38 PM   #215
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Sweet! Taking it to ipd?
I wish. I would need a solid month of daily driving/shaking it down before I'd attempt that drive.

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congrats! would love to hear some driving impressions when you have recovered lol
So far I've just been breaking in the engine by doing pulls/decel from 30-50ish. At first I had the wastegate hooked up and a jerry rigged throttle cable that made the car an on/off switch. That didn't work, so I unhooked the wastegate and have since sorted out the throttle cable to make it driveable. From what I can tell so far, it feels MUCH faster at about 1 psi than the old B18.

This car has a 4.30:1 axle, so it will break the tires loose at one psi without really trying. Quite a different car, and I haven't even gotten into the boost yet!

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WHOA! Congrats! Looking forward to Canepa!
Thanks! Hopefully I can get it cleaned up a bit. I forgot how gross a car can get when it sits for 7 months and you don't pay attention to anything but the engine bay.

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Good to see you finished this, and great fab skills also!
Thank you. I wouldn't call it finished quite yet, but this is a huge step. And honestly, there's no way I'd have made it this far without Noah doing the TIG stuff. I'll post some photos of the intake manifold later, he did an amazing job on that.
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Old 06-08-2017, 05:10 AM   #216
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Congrats on getting the beast running.

Yeah, I may be driving the '92 down to iPd, since I will have even less time after doing the swap on my 242 (doing this Sunday and Monday), so it likely won't be ready for the trip down on Friday.

-J
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Old 06-08-2017, 10:06 AM   #217
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I saw the instagram story, and got butterflies, this a great build, I still vote you break it in driving to IPD.
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Old 06-08-2017, 12:22 PM   #218
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I'm finishing my 8.8/t5 install this week and driving it to ipd, where's your sense of adventure!
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Old 06-08-2017, 12:58 PM   #219
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I'm finishing my 8.8/t5 install this week and driving it to ipd, where's your sense of adventure!
Ha! I have 250 miles on my B230ft/T5 swap in my '80 242, and last night I tore it all apart again to install a new clutch/PP combo, that won't even arrive until Monday! Should be fun.
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Old 06-08-2017, 02:06 PM   #220
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I'm not normally one to shy away from ill advised road trips, but this would be a real roll of the dice. Currently in this car are the first transmission, turbo, and engine that I've ever rebuilt, a rear end with way too much gear lash, and a host of other issues that I had deliberately forgotten about while doing the swap.

That said, I'm pretty excited to shake it down and sort out all these issues... within a 200 mile radius.
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Old 06-08-2017, 04:04 PM   #221
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^Either ride up with Pat, or use your daily...

Anyway, nice work.

-J
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Old 06-09-2017, 05:42 AM   #222
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Good for you. Lets see the finishing shot of the engine bay!
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Old 06-09-2017, 10:27 AM   #223
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WAY-TO-GO enjoy all of your hard work and good luck w/it!
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Old 06-09-2017, 10:43 AM   #224
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Thanks, guys. The engine bay is not quite finished, as I had to redo the IC to throttle pipe, so there's a unpolished steel (gasp!) one in there now. The idle motor also is not hooked up because of that, so cold starts are pretty annoying. I'll post some 'finished' pictures in a couple days.
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Old 06-09-2017, 02:30 PM   #225
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yeah its running! sweet.

I also don't have the idle motor fitted (plugged the holes), but cold start are no problem at all. when i cold start the car it fire's right away, and idles at 600rpm. when the engine is hot the idle is at 800.

is your brake booster in a good condition? i have had 4 140s and 1 of them had a good working booster, all the other where shot.
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