Posted: Tue Aug 19, 2014 7:23 am Post subject: 15 Window Splitty with AFN power underway!
Hi guys just a brief one to begin with as this is now approaching the stage where I start ordering adapters and fitting engines, but theres a fair bit more bodywork to be done first, so this is sort of a heads up!
Here she is in her current state then, the engine bay is done, but there will be trimming to do for the engine and box etc...
And here is the donor car...
I have one questions, as Im ordering a custom tank, can anyone tell me what lines I will need on the tank please as I would like these welded in from the start rather than retro fitted and messy??
Ive also got a few choice upgrades for the engine on order, so it should be fun
Thanks in advance, and I will try to keep this thread up to date as I progress...
Yep, you just need a feed and return. If you take out the boot floor/rear seat of the car, there is a round lid. Under here, the connections to the orignal passat tank can be seen, and easily measured.
If you bother measuring: The feed is 8mm and the return is 6 mm, inner diameter
At least, that's what is was on my 98 passat donor, also with AFN engine.
Are you using the flipped box conversion? _________________ 1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.
as for your tank, you need a feed and a return. Take a look at the tank in the Passat to see what the factory sized the bore of the outlets at.
I'm going with the flipped box route, already got the gear lever from a boxster, and the brackets, just need to order the adapter from Tim
Wilfred wrote:
Yep, you just need a feed and return. If you take out the boot floor/rear seat of the car, there is a round lid. Under here, the connections to the orignal passat tank can be seen, and easily measured.
If you bother measuring: The feed is 8mm and the return is 6 mm, inner diameter
At least, that's what is was on my 98 passat donor, also with AFN engine.
Are you using the flipped box conversion?
Awesome, thanks for that, really appreciate it! Getting one built by Bob at Concept Racing so he need the id's of the pipes, thats perfect. I will measure them tomorrow just to double check though.
Yep flipping the box for 5 speed goodness.
Radiator will be mounted at the front at 30 degrees to hopefully aid the cooling...
You want both the feed and return on top of the tank.
Return can just be any tube, that dumps the diesel in the tank. The feed should be a tube, to which you connect a hose with a filter a the end. The filter sould lay on the bottom of the tank, so the hose should be long enough to allow for that.
If you make the feed at the bottom, it's much more likely you will also pick up dirt, as it naturally flows to the lowest point.
If you take out the original passat fuel pick up thingie under the round lid in the boot, you will see what I mean. Good luck with that.
(oh, and the wires you will see under the round lid are just for fuel level indicator. you don't need em, so just cut em if they bother you) _________________ 1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.
Couple more bits done, mostly ripping the 3 front floors out!! Rrrrrgh!
Whilst its out, I am adding reinforcing so that the front end is all boxed in to the cage, also considering converting it to RHD, I know the downsides, but we will never intentionally sell the van and to us RHD has huge benefits...
Also, think we are swaying towards this as the final scheme, during the stripping process Ive found loads of og paint, and these was thems! So seems right to do it this way after what shes been through...
Heads up, bigger turbo is on order and new injectors too, just deciding on the intercooler position now so I can get the biggest one possible.
Managed to crack on with the front floor bracing, the gearlever mount, and the beginnings of the cage.
The cage has taken a totally different route. I had originally ordered a Baileigh industrial tube bender, and was planning to make the cage from CDS, but after many discussions with a trusted friend, about the purpose of the cage, and day to day practicalities, plus the issue of the money required for the tools alone, I decided to take his advice and make it from box section. It is not for race worthiness, or FIA scrutiny, its simply to keep the family safe, and to replace the strength lost from the bulkhead. It will also allow me to hide it a little easier as i have plans to integrate it with the furniture inside the bus, so all will become clear as the project progresses...
Anyway, here are the piccies, as that was a load of boring written stuff, which probably wont be read anyways!!
This is how I left it last time round...BARE!!
Since Im using a Porsche cable shifter, I needed to combine the bracing strength with mounts for the gear lever mech, so careful measuring was required and some funny angles too...
After a bit of buzzing with the welder, the frame was roughly in place, sooo time consuming though measuring angles and making it all look 'right' even though it will never be seen!
Tacked up the beginnings of the first hoop, its 50x50 box with a 4mm wall, so pretty strong
The seat frame is 40x40mm box, so it slips inside the front mounting point, and will be welded around the edge, just in case you thought the gaps were large, its an optical dillusion
Bit of etch before hometime, and thats all I have to show for 4 hours work!
Hung the frame for the seat from it too, this will not be a normal seat, but again, all will become clear eventually...
The cage is slowly coming together, i didn't take piccies of much of what I did to it but its almost a front hoop now, angles angles angles! They're a nightmare to get right, and we had to make new bushes for our bandsaw so that we actually get what we set it to, without it wandering off line, so that took a while...
The contact points on the chassis are just tacked into place, so the idea is, build it all up tacked, then remove it from the van, weld, prep, and epoxy it ready as i wont be able to reach the back once fitted in some places. Then I will weld in the braces once its fitted properly after the bus is painted and just do a localised repair, hope that'll work.
Onto the floor next. Complete revamp! Due to using custom, pedals lever, handbrake, in fact everything, plus having the cage welded directly to the chassis rails, an o.g floor just wont do. So I made some lovely templates...BORING... And transferred it to 1mm steel, first test fit...
Then I measured up and marked some outlines for the swager...
Sorted, then make a mirror imaged copy...
Ignore the miscut at the bottom, that will be remedied later on, its for a reason, honest, and pop them in ready...
The front will be different to normal, as im not lifting the cab floor up, it will have a kick panel mounted there, and will house a few goodies. The Boxster lever will be mounted beneath the floor, with a custom Ally H Gate on the floor being the only giveaway.
Also started work on the front cage/leg protection, but my phone battery died so only got one teaser piccy.
Got a little more done on the cage and got it mostly tacked up as I want it. From the side of the van, its all hidden behind the pillars so is as tasteful as I can manage with the circumstances. This part will now be removed and welded up and finished, then reinstalled, and the front hoop and door pillar supports added in a separate part, that will in turn be removed and painted as per the above post, then installed, fully welded in, and patch repaired. Here are the pics, only took them before I left so the light was awful sorry, just to prove Im not being totally lazy!!
This will be seam welded, so ignore the holes
Then bolted the gear lever in, its going to have to go beneath the floor though, as it looks mingin there!
So after researching cooling until my head hurts, Ive decided not to mount the Rad under the van in the usual place. I dont have access to a wind tunnel or a fully operational fluid dynamics simulator, so decided to do some calcs and try to do things the logical way.
I enquired with Bob at concept racing about getting a rad with the cores at the same angle as the airflow, but he said costs were ridiculous. So Ive decided on this...
With this, its balanced and no where near final placement but you get the idea!
Its from a 993 gt3 race car so should cool my 180 Bhp Diesel!!
So today I spent a fair time rebuilding my angle grinder, the bearings needed lube, it sound like a 777 on takeoff even with ear defenders!! When I did eventually get round to doing something, this is where I started...
Cleaned it all up and made room for the slightly holier mid section...
Got the one side finished, the other is tacked, but I will roll the van before I weld it in properly as I hate burnt hair! It stinks!
Then spent ages with a steel ruler, measuring where the inner and outer will be and putting the frames in the right places. This will look odd until I start adding sheet metal, but basically I want a large amount of positive pressure on the lower side of the rad, and a large amount of negative pressure on this side, that way the airflow will be sufficient to cool it all without stressing at the temp gauge...hopefully!
Finally tacked up the frame. The inside tub will have removable panels, for bleeding the tank and maintenance, but the underside will be sealed up, you'll see!
Heres the frame...
The escape hole at the back is for this...
...and the radiator, which already has helitape round it, sits in the frame perfectly! Like so...
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