OT: Working on my shop car, The wagon Porsche never built. . . Options

[aircooledtechguy]

I've had a long term project going now to turn my '67 Squareback into my shop car. While I love driving my 914, it has limitations as a daily parts hauler. I love old styling with new technology and updates, so my goal is to turn my humble Square into the wagon that Porsche never made. I want it to drive and handle more like a Porsche than a VW wagon and it's got to be a true "Sleeper" (not a real problem; since it's a wagon). (IMG:style_emoticons/default/shades.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689630.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689631.2.jpg)

This has been a 4-5 phase project.

Phase-1 - Convert it to Porsche 914 2.0L motor. Make it physically adapted to the car and running MS2 w/ Ford EDIS ignition. Get it tuned to be a daily driver. DONE!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689631.3.jpg)

Phase-2 - Make the motor look good and freshen it up with new P&Cs. The heads were freshened only about 2K miles before I got it, by me when it was in a clients 914 that he converted to Subie power. I noticed that once I had a few miles on it myself, it was using a bit of oil. So I upgraded to a new set of 96mm P&Cs. So now it's a 2056.




I had my local powder coater do all the tins in black and the plenum and runners in grey for a stock look. I'm running T-4 H/Es with a modified bus header and a Summit Racing Flow Master clone muffler. So I had those ceramic coated in black so they are not attention grabbers from the back. This car is a sleeper (IMG:style_emoticons/default/happy11.gif)



DONE!!

Phase-3 - Convert the rear suspension to the later style IRS and install a Porsche 923 trans out of a Porsche 912E. The rear suspension is DONE!! While at it, I upgraded it with 914 rear brakes, urethane bushings, adjustable spring plates and a rear sway bar. (IMG:style_emoticons/default/driving.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689632.4.jpg)

Since the trans is taller than a stock 4-speed and cutting into the car can't happen due to rear seat issues. I gained the 1.5" I needed by spacing the body off the rear suspension with spacers. So here I sit, on the final leg of phase-3. I now need to couple the motor/trans and lift it into it's final place and fab rear engine hanger mounts for the rear bar. It's late and I'm tired. . .

Phase-4 - Front suspension upgrade. Currently in-work

Phase-5 - Paint so it doesn't look so crappy, though it does add to the "sleeper" persona. . .

Stay tuned for more later. . .

[aircooledtechguy]

You need a custom emblem on the back ...VW-T314!!! (IMG:style_emoticons/default/piratenanner.gif)

Jack

I tried to order one from Jim a year and a half ago. . . (IMG:style_emoticons/default/rolleyes.gif) (IMG:style_emoticons/default/headbang.gif)

[aircooledtechguy]

Nate; Room for a V8 up front? Pretty Cool.

Not a snow-balls chance in a hot place brotha!! (IMG:style_emoticons/default/driving.gif)

[sean_v8_914]

super cool project

[Java2570]

Hey Nate - I love this build you're doing with the Squareback.....excellent stuff!! Jon

[aircooledtechguy]

Thanks for the kind words guys. I'm having a lot of fun making it all work in a new car. Can't wait to go driving. . . (IMG:style_emoticons/default/driving.gif)

[aircooledtechguy]

I spent my lunch today installing a set of 100mm wheel studs on my front hubs. The stock 45mm studs were not long enough to allow for wheel spacers larger than about 10mm, which just would not do. I was planning to run a pair of Porsche 944 21mm spacers on each side up front (42mm total) in order to widen the track so that it would be equal to the rear track. Actually, it only would take 1-21mm spacer in front if I weren’t planning to run 1-21mm spacer in the rear, but I wanted the flexibility of spacers front and rear if I decide to run a different set of wheels/tires in the future. So I ordered a pack of 10-100mm studs. I didn’t need longer studs for the rear since the Porsche 911 trailing arms already have 65mm studs installed for the factory 21mm spacers.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1373330191.1.jpg)

It didn’t take too long to remove the hub, then the rotor and finally the studs. Luckily I recently bought a 20-ton press so they came out and went in like butter.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1373330191.2.jpg)

Now with the wheel spacers installed, I have a track width of 64” in front and 64.5 out back; perfect!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1373330191.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1373330191.4.jpg)

Now I need to seriously stretch the fenders front and rear so everything fits.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1373330192.5.jpg)

Fortunately, this weekend when I was at the vintage races, I found a guy with a Mustang that had stretched his fenders almost exactly the way I want to do mine. For now, I'm keeping that close to the chest until it's done. I’m looking forward to getting that started after I button-up all the loose ends on the suspension.

[aircooledtechguy]

Finally!!! I got a bit of time today to work on the Squarsche.

I began with POR-15ing the fresh air vent assemblies. They were pretty crusty and since they are just spot welded together, I wanted to ensure they wouldn't leak (and corrode) in the future. Then I lubed the cables with a motorcycle cable lube tool and lubed all the hinge points. For the first time since I've owned this car (10 years), they will work 100% correctly.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380424791.1.jpg)

Then I had to install them which is easier said than done. . . Of course, the wiper assembly was already installed, so I had to first remove that.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380424791.2.jpg)

While the wipers were out, I decided to update the wiper pivots to the later style like the '71-on use. I was hoping to just swap out the early assembly for the later style and be done with it, but of course, the wipers are in slightly different positions compared to the early cars. :roll: So I removed the early pivots and cut the arms off. Then did the same to the late pivots and then welded the early arms to the late pivots. Then assembled everything back again. Since I like the extra spring pressure of the extra spring pressure that the late bus wiper arms have, I cut down and re-welded a pair of bus arms so that they were type-3 sized. I forgot to take photos of the process, but t's virtually the same as this:

http://www.aircooledtech.com/early_wiper_upgrade/`

When I broke for lunch, I received a call from a guy with a spare set of Porsche Boxter wheels cheap. So I picked those up so I can mount a set of winter tires on them. They are just the basic 17 X 7" & 8.5" staggered set.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380424791.3.jpg)

In order to comply with SCCA rules, I have to remove the steering lock mechanism from the lock cylinder. So I completely dis-assembled the Porsche 914 ignition assembly and removed the lock bar. Then re-assembled it with a new ignition switch since the old one was cracked. It fits like a glove in the shortened, '73 Super Beetle dual stalk column.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380424791.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380424791.5.jpg)

It was really good to get back on this again!!

[aircooledtechguy]

I had a little time last night to finish-up the brackets that allow me to mount the shortened Super Beetle steering column into the car. Now it fits well and has a solid feel.

This morning, I turned my attention to the steering shaft that connects the column and the Porsche R&P unit. It's just roughed into place at this point, but it's all there and works like it should. Woohoo! (IMG:style_emoticons/default/driving.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1380655788.1.jpg)

[aircooledtechguy]

I may not have had much time to dedicate to building the Squarsche as of late, but I have acquired a few parts. I recently took delivery of a massive box of random 1 5/8” mandrel bent tubing in preparation for building a custom header. Gotta love eBay!! I’m going to first have to build a set of custom stub pipes and then create an equal length 4into1 system for a special muffler I plan to use on the new motor.

I should be able to make a header or two out of this box of mandrel bent goodness. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1383000392.1.jpg)

[aircooledtechguy]

While my wife combat-shopped at crowded stores full of frantic holiday shoppers, I was hold-up at the shop, locked behind a prominently displayed "CLOSED" sign 20+ Gigs of music playing on shuffle and spent some much needed quality time with the Squarsche. MAN, did I need it; it felt great!!

I began by finishing up the firewall pocket for the Porsche 911 steering rack. The center 4" tube was tacked in, but I needed to fabricate the outer 8" or so to have proper clearance for the 930 turbo tie rods. I made some rough cardboard templates and then transferred them to sheet steel. Then I bent them by hand around some tubing. Tacked them in and then finish welded everything in place. Now I'm happy with how they came out and I have proper clearances when turning the wheels lock to lock.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.2.jpg)

Then I turned my focus to the forward suspension mounts. I wanted to tie the two mounts together with tubing side-to-side in a first step toward stiffening the front-end. In time, the center of this brace will also have the mount plate for a Braille racing battery (an effort to lighten the car AND shift the weight as far forward as possible to get the rear weight bias under control). I still plan to add a pair of braces from the uper factory beam mounts to the front mounts as well, but this is the main brace.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.3.jpg)

Then I turned to the pitman arm braces. This basic design idea was brought to my attention by "gearheadgreg" (Thank you!!) and is my take of a factory Porsche RSR style brace. I first made a cardboard template of the basic flat brace. Then I transferred that to 1/8" plate steel and cut it out with my plasma cutter. After smoothing the edges and trial fitting, it was ready for mock-up and mounting. Before that could happen, I had to drill out the taper in the Porsche pitman arm with a 14mm drill bit. Then I mounted up a 130mm long M14x1.5 thread bolt and set the proper height for the new braces. Then the bare arms were tacked and then finish welded in place. The arms are strong, but I wanted to ensure they wouldn't deflect when highly stressed, so I took some 1/2"x1/8" flat steel and boxed-in the new braces. I first ground the inner edge so I could get good penetration when welding Then I tacked one end and bent it around the perimeter, tacking it as I went. Once it was all in place I finish welded a bead all the way around it. I plan to add one large gusset unter the brace between the pitman and the brace for good measure, but I ran out of time this weekend. With this set-up, I'll be able to tailor the bump-steer by simply switching around some spacers so the tie rods have the desired angle. It should work pretty good and be simple to make adjustments. Here's some shots of the process. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.6.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.7.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964198.8.jpg)
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(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1385964199.10.jpg)

[jaxdream]

Dadgum , this is just plain slicker than socks on a rooster !!!! (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif)
Keep it going dude !!!
Jack

[zambezi]

Great job, and nice to see more progress. I know the sloping nose of the earlier type 3's is more appealing but if you had started with a 70 - 73 model the front suspension pickup points would be totally hidden. Love the fabrication going on here.

[MDG]

Dadgum , this is just plain slicker than socks on a rooster !!!! (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif)

(IMG:style_emoticons/default/ohmy.gif)

(IMG:style_emoticons/default/mellow.gif)


(IMG:style_emoticons/default/smilie_pokal.gif)


I have no idea what that means but I will use that line.

[aircooledtechguy]

Thanks for the kind words guys.

Zambesi; actually the front end only appears to be longer on the late model cars due to the area above the bumper sticking out further. The area the suspension actually mounts to is just as long as the earlier cars. No way, I'd roll in a fat-chick Square. . . I just can't get past the looks of that nose. (IMG:style_emoticons/default/laugh.gif) (IMG:style_emoticons/default/shades.gif)

I never liked the location of my 4 gauges that I had mounted to the left of my dash since I really couldn't see them unless I leaned forward and peered over the spoke of the steering wheel. To be honest, it was always a temporary location to get it on the road until I found a better solution. So, I had a good friend of mine that builds racing sail boats, build me a prototype center gauge panel for the Squarsche. I'm not a fan of full center consoles mainly because they get in the way of my "Bozo-ish" feet and they tend to make a car feel smaller by being less open. So I opted for a center/right custom panel that could house my gauges. Then to angle them up slightly and toward me, I fitted a set of S/S angle mounts that I purchased (and never used) when I was stationed in the Philippines back in 1990. All the Jeepneys had these for the gauges on the dash and finally I have a perfect use for them. So if you're an old-timer like me and have ever ridden in a Jeepney, those will probably look kinda familiar and may bring back some memories. . . Now I will have a perfect view of the gauges at all times at a glance.

Some photos of it all mocked-up. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1386703073.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1386703073.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1386703073.3.jpg)

[Chris Pincetich]

(IMG:style_emoticons/default/beerchug.gif)
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[aircooledtechguy]

So this week I focused on the rear engine hangar and the engine mounts among other things. I’ve got some severe torture in store for this car in the near future, so when I install the new motor, I’m not willing to continue running the factory rubber engine mounts. These don’t last long in a stock bus 2.0L w/ 70hp and I’ve been punishing them long enough with my Porsche 2056cc that’s probably putting out a mere 100-110hp. I don’t want to risk them with a race-prepped 2.3L running MS3 and COP. So I opted to modify a set of bus rear engine mounts and a bus mount bar (since that’s what I’m currently running) and make it a solid mount arrangement.

For this, I bolted together a mock-up motor to my engine stand so I could ensure everything fits 100%. Finally a shop full of crap pays off!! (IMG:style_emoticons/default/lol-2.gif) I’m also in the process of making my stub pipes and exhaust, so some of these features will be incorporated in since they also use the mount bar, however, I’m not going to be letting that cat out of the bag just yet. . .

Here’s a few photos of the solid mounts. These should transfer a lot more engine noise into the cabin. . . Oh well, it’s the cost of being able to go *really* fast. Nothing ear plugs can’t handle.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387071149.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387071150.2.jpg)

Here’s a couple shots of the almost completed mount bar with the part of the custom exhaust hangers welded in place. I'll let you all speculate as to what exhaust I'll going to be running. . . (IMG:style_emoticons/default/shades.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387071150.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387071150.4.jpg)

I’m only letting on to about ½ of what I’ve been up to recently. . . Stay tuned for the rest of the story. . . (IMG:style_emoticons/default/shades.gif)

[scotty b]

(IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/smile.gif)

[aircooledtechguy]

With the new, more powerful 2.3L street/race motor that’s going in the Squarsche, I needed to upgrade to a full-on performance minded exhaust. So the stock type-4 heat exchangers and off-the-shelf bus 4into1 header was not going to cut it anymore. Since there are not any affordable systems that will work, I opted to make my own so it would fit and incorporate the muffler I wanted to use; a Bischoff S/S Porsche 911 banana can!

So I began by creating a set of stub pipes. I chose to use 1 ½” pipe for the stubs and 1 5/8” for everything else before the collector. I also wanted to try out a new idea that’s been rolling around in my head that would enable me to have leak-free stub to header connections. It involves 2 slip-joints, which cause any exhaust gasses that wish to escape to have to turn 180 degrees, then another 180 degrees and finally another 90 degrees for a total of 450 degrees all in a millisecond; that just isn’t going to happen! So these stubs will be leak-free while being exhaust gasket free too. They were kind of a PITA to make, but they came out exactly as I envisioned and they fit the bill perfectly. I still have some finish welding to do on the flanges and cleaning up on the flanges, but you get the idea. . . Once it's all tacked together, I'll go back and TIG weld every joint.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.2.jpg)

When building an exhaust, you have an obvious starting point for the system at the heads, but you also need to have an ending point so you can figure out how to get it all to fit. So next I mounted the muffler. Since I had never seen a 911 banana can muffler on a VW engine, I needed to come up with a muffler mount system. You just can’t mount it to the fan shroud since it’s not really made for mounting anything larger than an AC compressor, your mounting options become limited. So I decided to make the mounts attach to the main engine mount bar which is the main load bearing member at the rear and is tied into the body of the car.. The right side mount I made from ¼” steel since it has to bear the full weight on that side and the lions share since that mount is about 1' off center-line.. The left side I made out of 1/8” steel, but tied it into the AC compressor mount holes that already exist in the fan shroud. I cannot tell you for sure just how many times I mounted/dismounted the bar and fan shroud during the build process, but it was at least a couple dozen! Everything was dry fitted, then welded in place to ensure a perfect fit.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.3.jpg)

Once the bare mounts were made, I needed to make a pair of cradles where the muffler will sit. I chose aluminum for this since it needed to be ¼” thick and steel would just be too ridiculously heavy for this part. All the mock-up was done with the engine sitting on my lift about 10” off the ground with the muffler sitting atop wood bucks that held it at the right position. One of the goals with this exhaust is to not have any part of the system below the bottom of the engine. Ground clearance can be an issue with the car lowered and I got really tired of my exhaust scraping occasionally as I exited a couple parking lots in my town. Plus this car should see a fair amount of track time in the future and I'll be lowering it on those occasions.

Mount holes were drilled through all materials at once so there was no chance of bolts not fitting or fitting loosely. The result is a super-solid mounting that does not rely on the tightness of the bolts to be a tight fit. Here's a few shots of the muffler cradles in place on the mock-up motor:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.6.jpg)

Here’s some shots of the muffler in place on the new cradle on the mock-up motor:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.7.jpg)

Strapped on with temporary straps:

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329628.8.jpg)

I also modified the muffler to exhaust mounting with a V-band coupler so that for track days I can easily remove the muffler and add on a Supertrapp or more basic flow-through muffler/stinger system.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1387329629.9.jpg)

Now that I have a definite beginning point and ending point I needed to locate where the collector would be and begin building to the rest of the header. Stay tuned. . . 8)

[914werke]

Crazy!

[bigkensteele]

(IMG:style_emoticons/default/piratenanner.gif) I love this thread!

How much room will there be between the fan pulley and the muffler? Are you concerned about cooling the engine with hot air?

Just curious as you have obviously thought this through.