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Bay Window with 1.9 TDI engine -> READY
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Kai
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Location: Village life.... Enter the Vale

PostPosted: Fri Feb 19, 2016 7:43 pm    Post subject: Reply with quote

Knowing what I know now........ With my cheetah I'd go subarugears with a H6. The Subaru gears I have in my notchback is wicked and trouble free. I can complain all day long about my flipped gearbox but I know I'm a special case with my extra large Cheetah.

Dare I say it, I'd even considering doing an t25 auto setup, RJES bell housing with a Subaru H6. I'm getting old and extremely lazy.
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Last edited by Kai on Sat Feb 20, 2016 7:28 am; edited 1 time in total
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richbaker78
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PostPosted: Fri Feb 19, 2016 8:40 pm    Post subject: Reply with quote

Subarugears is a great idea but it's big bucks really.

Some options you haven't considered - use a golf / rabbit with transverse set up - this has been done. There's a guy on here and vzi.

Cut the fuel tank shelf out and mid mount the Passat engine with the gearbox the right way round.

Both cheap but labour intensive options which in hind sight if I were starting again I would probably do the latter but with Subaru stuff.
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splitbusvanatic
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PostPosted: Sat Feb 20, 2016 12:54 am    Post subject: Reply with quote

The flipped box is tough going with the bay or split bodies being so narrow compared to the t25's.
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Wilfred
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PostPosted: Sun Feb 21, 2016 10:54 am    Post subject: Reply with quote

I really have no complaints anymore about the flipped box.

okay at first I had some trouble but that was my own fault.

- leaking (wrong breather setup, fixed)
- lack of power ( air flow sensor wrong way around)

Now all is good, and with a new turbo it just runs really great. Plenty of power and relaxed cruising. Although I have to admit that the real long travels are still to come.



I wanted to fit bigger tires but that was wrong. The baywindow tires are already bigger than the original passat tires. Fitting even bigger bus tires just made it really slow.

Kai, what size tires do you run?

I really want a scrapper gearbox to mess around with though. I have some ideas which I thank may work. But dont want to take mine out of the bus, I need an extra one which can be scrapped.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.
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Kai
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PostPosted: Sun Feb 21, 2016 3:34 pm    Post subject: Reply with quote

Originally I had 255/50/16 I think. These where okish. Still struggled to run in 5th gear at times.

Now I'm on 285/35/18 as I wanted a high load rating and the 255/50/16 is not a common size tyre nor load rated enough. This has taken the gearing up and pretty much written off my 5th gear completely. Not researched it but I would contemplate swapping out my ring gear to drop the entire gear set down abit. Of course there is the quest for more power which I have not begun yet but doubt I'll every be happy.

Monitoring my intact temperatures I hit 98 Celsius climbing a hill in 3/4th. More power!!!!!!!
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Wilfred
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PostPosted: Sun Apr 10, 2016 5:02 pm    Post subject: Reply with quote

I took the van out last week. Had been standing in storage for months. didn't even disconnect the battery. Yet she fired right up at the first tick!

I improved the gear controls. I used a bad u-joint, with a lot of play and there was play on more parts. It was difficult to find the gears at times. Took it al out, made it (near) perfect and now I can honestly say it shifts better than with the stock gearbox. Really a joy to drive.

I also added a turbo pressure gauge! interesting to see. All seems to be fine. Turbo pressure is there when it should, for example when flooring it.

I look forward to a trouble free bus season!

only thing I am gonna do still is lower the van to decrease the drive shaft angle, and compensate this with slightly bigger tires to maintain ground clearance.

And do some stuff to the camper interior maybe....
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Wilfred
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PostPosted: Fri May 06, 2016 9:41 am    Post subject: Reply with quote

so, I wasn't all to happy with the driveshafts. Familiar issue with the TDI with flipped box, but still.


Just cruising along it is fine but in corners, I could here the CV joints knock. I absolutely do not want to lower the van. We go camping in the wild often, so I need ground clearance.

I already tried (way) bigger tires (plus 10 cm) but this made it worse to drive as it messed up the ratios and left 5th gear useless.

Recently, in the topic by splitbusfanatic I mentioned heavy duty driveshafts for offroading etc. Real nice ones.
these:

only drayback is that they are 1200 dollar for a pair. Insane.

But the design stuck in my head, so today I offered up an jaguar xj6 driveshaft. Made up this:



similar to the 1200 dollar set (off course needs to be welded still). under the rubber is a splined part which allows it to stretch and compress. In total 5 cm play. Less than the 1200 dollar ones, but my guess is that it is plenty for under my van. A lot more at least than the original driveshafts have!

the angle is way bigger than the original cv's can make.

and the diameter off the flanges is virtually the samen. Pic below shows VW flange on the right and xj6 flange on the left.

. almost exact same size.

All that is left is welding them together, with a piece of pipe inside or outside as a sleeve, drill extra holes in the flanges as the bolt patterns differ (but most importantly, the space for extra holes is there so should work out fine). Then see how these do. If it works, I will have them balanced.

for now, it feels like this might work. but first, fingers crossed.
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trev
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PostPosted: Fri May 06, 2016 6:37 pm    Post subject: Reply with quote

looks interesting! keep us posted Happy
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splitbusvanatic
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PostPosted: Fri May 06, 2016 10:07 pm    Post subject: Reply with quote

You could be nearing "HERO STATUS" with this little experiment.
Dying to see how this turns out.

The problem with the bay window bus and split bus is they have such a narrow track compared to the t25/t3.
I think the t25/t3 is almost 5 inches wider of a track.
The narrower track of the type2 equates to a steeper angle.

For me it's a real disappointment in the flipped gearbox phenomenon.
It's why I haven't spent money on adapters.
Time: yes,
Money: not so much.

Really looking forward to this one.
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splitbusvanatic
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PostPosted: Fri May 06, 2016 10:23 pm    Post subject: Reply with quote



Is this one drive shaft cut into two pieces or two shafts cut up and ready for mating together. ?
Also. What year Jag ?
Thanks.
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Wilfred
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PostPosted: Sat May 07, 2016 6:34 am    Post subject: Reply with quote

Yes, these are both ends of a single driveshaft.

This driveshaft is fitted under the jaguar xj6, series 1,2 and 3. From the years 1968 up to 1987.

I have a second one already here, as I scrapped a couple of these cars. Over here, especially the later xj6's are cheap, so parts can be picked up for little money.

But the design of this driveshaft is similar to any rearwheel drive car with the engine in the front. Maybe there are other cars with possibly even better flanges or even cheaper parts?
For me, I choose these simply cause I already had them!
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ricola
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PostPosted: Sun May 08, 2016 8:12 am    Post subject: Reply with quote

when you weld them back together make sure you 'phase' the ends properly!
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