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Thread: VW Cabriolet Project for the wifey

  1. #551
    Sr. User Array maxwell's Avatar
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    Quote Originally Posted by juicedz4 View Post
    Good thought. Maybe I can get some pre rusted?
    Old cut up soup cans and coat hangers from the dry cleaner has my vote.
    MAXWELL
    BLAOWW!!

  2. #552
    Sr. User Array juicedz4's Avatar
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    Got the back third of the exhaust welded up last night, minus an actual tail pipe. Was my first time welding SS. Its def not the best work ever, but Im happy enough. I had some moments of glory on the hanger.























    Dan

  3. #553
    Sr. User Array juicedz4's Avatar
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    Didnt get really any time to work on this on my week off but I did test fit the exhaust. The one hanger turned out perfect.





    And I tried out a maroon surface conditioning belt on the tubing. It looks pretty good, but not quite brushed enough. Im gona give a brown belt a try and see if thats better. Still unsure how Im going to de-polish the muffler and resonator.





    Built a new table for my horizontal bandsaw as well as a sled for cutting tubing as Im going to need to do a new downpipe soon.











    And spent some much needed time cleaning up the shop. I took down the booth for now as its annoying and easy enough to set back up.





    Dan

  4. #554
    Sr. User Array juicedz4's Avatar
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    Worked on the exhaust some more over the weekend.


    Finished welding up the midpipe. I feel like Im getting better on the welds, more consistent etc.


    Inlet Vband





    I swedged the pipe after the resonator to match which made for a pretty easy weld.





    Outlet vband





    And there is it








    Of course I didnt like the inconsistent finish or the color from the welds (weird I know). So I sanded out all of the tooling marks and then did a brushed finish on it with a maroon belt on the Dynabrade. Much better











    [img][/img]




    Then I needed to make the last mount for the muffler.


    Welded a little tab onto the rear muffler flange, bent up a piece of 3/8" ss rod and boom. The rod is welded to a plate inside the trunk that I tacked in a few spots (no pics).










    Friday I picked up the rear axle beam and associated parts from the powder coater. Im pretty stoked how it turned out. I will need to pull the bracing back off to install everything on the car but I just needed to see it together.













    Dan

  5. #555
    Regular User Array lorge1989's Avatar
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    Using a back purge setup I assume?

    1994 Audi 90 V8 - 1988 Audi 90 MS3X - 1978 GMC High Sierra

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    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by lorge1989 View Post
    Using a back purge setup I assume?
    Yuppers. Wifey got me the dual regulator for xmas.

  7. #557
    Sr. User Array juicedz4's Avatar
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    Put the brushed finish on the rear exhaust section last night. All thats left now is a tail pipe which Im still undecided on.











    Dan

  8. #558
    GIMME DA COOKIES Array JayS's Avatar
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    The level of detail on this thing continues to amaze me. I'm in my 40's and hope I live long enough to see it completed.

  9. #559
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by JayS View Post
    The level of detail on this thing continues to amaze me. I'm in my 40's and hope I live long enough to see it completed.
    You and me both pal!

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    Sr. User Array juicedz4's Avatar
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    Not much progress in the last month, just too busy doing adulting.


    Did manage to create the front exhaust mount and get it tacked on. Also have the end of the down pipe done (flex section and transition from 3" to 2.5")








    And some parts showed up.


    First $185 order of ARP hardware.





    3" stainless for the new down pipe





    EFR 6258 turbo finally showed yesterday. The T25 inlet and 3" outlet makes for an odd looking setup. But its going to be a MUCH better choice than the T3 turbine'd super 16G that I had originally. Excited to start getting it installed next week.













    Dan

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    Sr. User Array maxwell's Avatar
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    MAXWELL
    BLAOWW!!

  12. #562
    Formerly 'gotdubd' Array manhagen's Avatar
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    This build is one of the only reasons I even sign on here anymore.

    If you need help in the wheels and suspension department when it comes time, please message me. I mainly do air ride stuff, but can also get KW/ST suspensions as well fifteen52 wheels.
    ****

  13. #563
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by manhagen View Post
    This build is one of the only reasons I even sign on here anymore.

    If you need help in the wheels and suspension department when it comes time, please message me. I mainly do air ride stuff, but can also get KW/ST suspensions as well fifteen52 wheels.
    Sounds good. For now I have brand new Bilsteins, Autotech springs, and some knock off wheels I bought back in like 2007, lol.

    At some point I may do coilovers if the ride isnt right.

    Dan

  14. #564
    Sr. User Array juicedz4's Avatar
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    Originally I thought for sure that the new EFR turbo would fit very similar to the old 16G given the basic size. Fortunately it would not which led me down a huge rabbit hole (as usual).


    This was the original setup:







    Turns out the best way to fit it was to flip it around. This meant having a different intercooler. I couldnt really find anything that I liked that would fit well with in/out on the same end. So I thought why not go water to air. And well, here we are.


    First I came up with a wood jig to hold the turbo in place.





    Then found an IC I thought would work and made a poster board mockup of it. Scabbed together a bunch of random couplers and hoses and decided I could make it work.








    Fast forward to a bunch of parts showing up.


    Needed to modify both the inlet and outlet of the IC which required both flanges to be removed. To avoid getting any metal inside I connected the shop vac to blow through while cutting. It worked perfect.





    One side cut





    Cast inlet elbow cut





    For the outlet I wanted to match the 3" dia of the TB, so I cut and formed a piece of 3" tubing to the outlet of the IC








    Was "talked into" using the Vibrant HD wiggins type clamps instead of couplers and tbolt clamps. So got those welded onto the IC and TB late last night.








    Placed in approximate location. Im still short another cast elbow that I need to weld to the turbo, but I cant go much further until I make a manifold.











    Im super stoked how its turning out. Its soooo much cleaner than what I had originally.


    As for the manifold, Newman was gracious enough to model it for me using some basic location dimensions. I ordered the weld els for it today, they should be in later next week along with the head flange.








    Dan
    Last edited by juicedz4; 09-15-2017 at 02:31 PM.

  15. #565
    Lifetime User Array ubengineering's Avatar
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    IDK how a few of you guys on here that are capable of this level of craftsmanship aren't millionaires with self running businesses.
    15 Focus SE - 01 S10 4.3L - 96 Viper GTS - 95 Neon R/T

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    Lifetime User Array focusinprogress's Avatar
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    Quote Originally Posted by ubengineering View Post
    IDK how a few of you guys on here that are capable of this level of craftsmanship aren't millionaires with self running businesses.
    It sucks dealing with other people's projects, expectations, impatience, and lack of wanting to pay fair money for services rendered. it's not worth it lol.

  17. #567
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by focusinprogress View Post
    It sucks dealing with other people's projects, expectations, impatience, and lack of wanting to pay fair money for services rendered. it's not worth it lol.
    This. Plus youd never want to work on your own shit.

    Dan

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    Quote Originally Posted by juicedz4 View Post
    Originally I thought for sure that the new EFR turbo would fit very similar to the old 16G given the basic size. Fortunately it would not which led me down a huge rabbit hole (as usual).
    Not just a great fabricator but also very punny.

  19. #569
    Sr. User Array juicedz4's Avatar
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    Whipped up a new fan shroud for dual 10" Spal fans last night. Just need to add the mounting tabs which I should have today.


    Bent up the 0.090" sheet on the brake at work.


    Then welded and shaped the corners. I backed up each corner with a small bent piece of aluminum welded to the backside.


    Cut the holes out with my handy Bosch jig saw and cleaned them up with the floating belt on the Dynabrade (best tool ever). Finished with 180 on the D/A and then a red scuffy. Im gona feel bad having it powder coated, maybe.




















    Dan

  20. #570
    Sr. User Array juicedz4's Avatar
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    Finished up the fan shroud.


    A friend cut the mounting tabs on his CNC which saved a ton of time trying to get 4 exactly the same.


    I hand filed the shroud to accept them, and welded them on the backside for a clean look. This will ultimately be powder coated wrinkle black.

















    Installed with the top cover I formed a few weeks back





    With that done it was time to start on the collector for the manifold. I managed to get two of the tubes cut and fit pretty nicely. The other two got borked up somehow (the first two I did) so I need to redo those tomorrow.





    Dan

  21. #571
    Sr. User Array juicedz4's Avatar
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    Finished up the collector last night. Fit turned out pretty nice for my first time I think. Also got the bends and straight pieces cut so its ready to assemble. Should be starting on it tomorrow night if the head flange shows.

















    Dan

  22. #572
    Sr. User Array maxwell's Avatar
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    pro.
    MAXWELL
    BLAOWW!!

  23. #573
    President: Big Cat Club Array newman's Avatar
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    Did you make a fixture to cut the elbows?
    Icecream Paintjob

  24. #574
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by newman View Post
    Did you make a fixture to cut the elbows?
    Not really. I drew some circles and lines on poster board and used that along with a square to mark them at approx the right angle. Then cut them on the bandsaw and sanded smooth.

    I figure I can tweak them as needing during assembly.

    Dan

  25. #575
    Sr. User Array juicedz4's Avatar
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    Head flange came in yesterday but its wrong, so I decided to work on the valve cover project last night.


    Recall that I had two covers baked and blasted a while back. And did some milling to fit the COPs.







    Ill spare you the details of cutting and fitting the piece from the donor cover and start where I had it clamped in place for welding. I welded both sides, then ground and sanded it smooth. Just a few pin holes were unearthed after grinding, which I'll likely just use some filler on vs trying to weld since Im pretty positive this is going to be painted.


    Im pretty stoked how it turned out. I still need to remove the extra tabs and likely decrease the radius of the top pulley guard as Im not going to be running a timing cover.











    Dan

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