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My 1303 with EJ20T and G50 Transmission
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Thu Feb 24, 2011 9:38 pm    Post subject: My 1303 with EJ20T and G50 Transmission Reply with quote

Hi

To save everyone going to German Look or Aussie Veedubbers I'm going to start a thread here, but 1st some history.

I've been building a 1303 for the last 6 years. I just got it back from the paint shop, still putting it together.

I used to have a build thread on my car clubs website but that's gone now, so I will add what I can here.

Basically its 1973 1303, it was given to me 2002, I started working on it on & off in September 2004.

I've fitted the brakes from my old 1302, 996 rears on the front with 930 rotors, Boxster rears with 944 rotors. My old 1302 ran 2.1 turbo WBX.

86 alloy arms, G50 transmission & 2003 2 litre STI, 18x8 Simmons wheels etc

I originally had a 1302, I bought it 2nd hand in 1973 when it was 6 months old. I evolved this car with a turbo 2.1 Wasserboxer, 944 rear end and with the brakes I've now fitted to this 1303.

John Polden the original owner of the my "new" 1303 and I worked together for some time at a Sydney performance VW shop called Powertune. We have remained friends over the last 30 odd years and when John decided to move to Queensland Gold Coast I was lucky enough to be in the right place at the right time to obtain this car. The car was sold to V Force and stripped of its goodies then Richard at V Force gave me the rolling shell.

I've kept a lot parts from my 1302, brakes, suspension, seats, cooling system parts etc. Rather than use the water-cooled Transporter engine again, I have purchased 2003 Subaru WRX STI engine which has only done 13,000 kilometres to fit to my new project. 195 kW+ from the factory should make for an interesting ride. In place of the modified Type 1 box I'm now using a G50.

John Polden the original owner of my 1303 competing at Amaroo and Silverdale Hillclimb (blue car photos below) in the early 1980s, it was a street car then, running a 2180 cc Type 1 motor with 48 IDAs, it gained many FTDs at various speed events and it used to do the 1/4 in mid 13s back in the early 1980s. John later fitted a Mazda 12a rotary motor that first saw duty in a Group C touring car, John then ran the car as a sports sedan. The Beetle was put in his shed in 1985, when John decided to move to Queensland he sold the car to V Force, then I acquired it from V Force.

Steve

Photos, yellow bug is my old 1302, blue bug is the one I'm rebuilding and is now orange






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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Thu Feb 24, 2011 9:50 pm    Post subject: Reply with quote

Hi

More history, sorry if I'm boring anybody.

This car had not been driven since 1983 and was virtually rust free, I acquired this car in 2002 and then brought it home in September 2004 after it had been sitting in a friends shed, I had sold my yellow 1302 earlier in 2004, I always wanted a 1303.

The previous owner had fitted rack & pinion from a 75 bug. and cutout the spare wheel area to house a radiator.

More old photos.

My STI motor had only travelled 13000 ks and my G50 came from a low mileage Jap import.

I moved the motor and transmission forward 100mm, had to cut the torsion housing and I ended up using 40 hp length 26 mm sway away torsion bars, I had a stroke of luck, the G50 shift rod turned out to be exactly the correct length.

Steve











G50 compared to a stock trans, an old one from under the house.


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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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Alex (FTS)
Jedi Guardian
Jedi Guardian


Joined: 06 Feb 2006
Posts: 993
Location: Falmouth, Cornwall

PostPosted: Fri Feb 25, 2011 9:31 am    Post subject: Reply with quote

This looks like an excellant idea! I love all the history around your car too! Keep up the good work-cant wait to see more!
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Fri Feb 25, 2011 2:20 pm    Post subject: Reply with quote

Hi

The G50 is very hard to keep stable on a jack, so I made this bracket to hold it on my jack.



I've used the stock G50 alloy mount, I welded some tabs onto the chassis for it bolt onto and I had move the mounting slightly using some aluminium blocks.

I cut the centre spline from 2 chassis and had an outer sleeve made.



I welded the splines in with "rose bud" welds so that 40HP / 1500 Beetle length 26 mm torsion bars poked out the correct amount to mate up with 944 spring plates.



I will get to the newer stuff soon.

This is how the reinforcing started off on the torsion bar housing.





I widened the engine bay area around the bumper bracket, my motor has variable valve timing there is a huge lump on the left rear cam cover that I had to be careful to make room for. Here you can see how close the cam covers come to the rear apron, even with the motor 100 mm forward.













These motors are real tight fit and are also a pain as they want to fall off the jack all the time, that's why I made motor dolly with wheels, it bolts to the exhaust ports oin the bottom of the motor. Even when the motor is sitting on the floor it wants to fall over onto the flywheel. You will notice that I have jack stands under the engine dolly, this is to prevent the weight of the motor tipping the car over backward, might not happen, just being careful, it actually did happen to me while fitting a motor to Notchback that no front-end in it.



I used this Bay Window Kombi transmission frame that I bought at the Valla swap for $5.00 to give some extra support for the transmission, this will also be useful to keep the transmission steady when the motor is removed.

Steve
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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 12:28 pm    Post subject: Reply with quote

Hi

A friend had a PWR air 2 water inter cooler that he wanted to sell as it was too big for his project. Its a 6 inch by 10 inch unit which is rated to 650 hp. Needless to say its ideal for my car.

I finished the inter cooler pipe work today, Brad a Westside Mufflers in Padstow did a great job with aluminium welding, I will only need to plumb in a blow off valve now. Now I can concentrate on getting a firewall made up to cover all this stuff up. It made it much easier working with everything exposed this way. The back seat will need to have a bit of a hump in it. I will be using the Grocco water pump from my old yellow car and a Subaru RX intercooler radiator in the front of the car. As you can see the charge air will have a very short path.

This is the Grocco water pump from the old yellow bug, which I will be reusing to circulate the water in the intercooler system.






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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 12:31 pm    Post subject: Reply with quote

Hi

1303 or L bugs as they are called in Australia, have a history of body damage being caused when the circlip that holds the bonnet/hood falls off. To overcome this problem I drilled out the original circlip stud and fitted a bolt instead. This is fairly easy on passenger side, but on the drivers side I needed to cut a larger hole with a hole saw.




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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 12:35 pm    Post subject: Reply with quote

As Im running a bit of angle on my CVs I had the 944 stubs altered to take 930 CVs.

I was going to use some replica Porsche 17x7.5 23ET wheels that I bought on Ebay. The 23 ET is an unusual offset, I believe that these were made to suit early 911s and 944s as a 7 inch Fuchs or Cookie cutter has the same ET. So these wheels being a 7.5 they protrude an extra 6 mm each side of a 7 inch Fuchs.

On my old 1302 I once ran 7x16 23ET inch Fuchs on the front and 8x16 10.6ET on the rear. I know the fronts will be OK, so after adding in the wider track that the rear alloy 944 arms give me and doing some calculations with an online wheel offset calculator, I worked out that these wheels should fit OK. I did a trial fit today with an Aero mudguard held in place and it all looks OK.




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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 12:46 pm    Post subject: Reply with quote

I planned to put a Beesting radio aerial on the roof from a late model VW, but I was worried about future access to the aerial.

I forgot post the Beesting photos,





On the later VWs it's possible to pull the hood lining down to repair or service the aerial. That's not possible with an old bug, so I came up with the idea making a frame that will sit under the hood lining but will accept a standard Beetle interior light, so if I need to service or replace the aerial I will only need to remove to interior light to gain access to aerial securing nut.

I had a friend make these pieces up to weld into the A&B pillars to give the body some strength. I made a cross brace between the B pillars, a bit like factory cabrios use. You might also notice that the previous owner had filled in the running board area with a reinforcing piece.






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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc


Last edited by 1303Steve on Mon Feb 28, 2011 11:02 pm; edited 1 time in total
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 12:49 pm    Post subject: Reply with quote

As I'm getting old and soft, I'm fitting air conditioning, plus it gets hot down here.

The evaporator will sit in this box behind the dash, I will need to move the radio, maybe to the bottom of the dash.








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STI powered 1303 now running
G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 1:01 pm    Post subject: Reply with quote

Measuring up for some custom axles, had these wooden ones made from 30mm dowel.



Brad (Westy) at Westside modified my Subi sump for me after I found that the bugs at 5 speed wouldn't fit with my combo.




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G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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Shrek
Padawan
Padawan


Joined: 27 Nov 2010
Posts: 53

PostPosted: Mon Feb 28, 2011 10:16 pm    Post subject: Reply with quote

Like the door bottom and other strengtheners fitted inside, sump looks good too but not too sure about heater matrix - looks heavy if you need that trolley jack to lift it!.
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1303Steve
Jedi Knight
Jedi Knight


Joined: 07 Aug 2009
Posts: 204
Location: Sydney, Australia

PostPosted: Mon Feb 28, 2011 10:48 pm    Post subject: Reply with quote

Hi

Thanks for the replies, that's actually the aircon evaporator, I will just need to up the boost to compensate for the added weight Grin

Steve
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G50 box, Boxster/944 brakes, Adaptronic 1280E ecu, PWR intercooler etc
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