Mittwoch, 29. April 2020

Oil cooler project finally finished!

After lots of angle grinding, hole drilling and thread cutting, it is finished!
Some details of the 3mm steel plates I used for the brackets (again, captive nuts were used)

Here is the cooler already fitted, the oil lines are not finished yet in this pic (another set of 6 captive nuts in hindsight of a cover with vents, to be mounted later)

And a view from the side:

And the finished article, plumbed and oil tight!

Currently I am designing a metal shield with cooling fins to improve the already good airflow even more!

Besides the improved cooling abilities, I also wanted to get rid of the "chaos" in the engine bay, I think it worked out well:

before:


after:

(Yes, I know, the vent hoses looks like garden hose, but it was supplied by CB performance, with the Type 3 specific vent housing. It will be replaced with "proper" hose soon!)

all of this cluttered mess is gone:


Here are a few shots of the creating, fabricating and assembly process:



This is the initial sketch - for me, most of it still makes sense, even though, I changed a lot of details along the way...

I also added another piece of sheet metal to improve air flow on the 3/4 cooling tin. There is a rectangular opening to release the hot air, after it passed the oil cooler, here is a pic of such an original cooling tin:

This opening could be closed, now that there is no oil cooler any more, it will improve the cooling of cylinder 3/4 as more air volume will flow over the cylinders now.

Here is the metal cover, I used a simple tab on one side and an existing thread on the other side, thus I could slip the cover onto the already mounted tin:


This is a mock up of the final assembly set up:
 (Of course, the cooling tins on my engine are not that messed up and rusty!)

Dienstag, 21. April 2020

The first cut is the deepest

The oil needs to travel from the adapter to the oil filter, behind the firewall. A hole in the fire wall is a first step. (A lick of rust protective primer hopefully prevents rust on the cut line). To make this mess a whole neater, another aluminium cover, painted in black wrinkle finish, equipped with proper rubber grommets to protect the oil lines was fabricated. M6 Captive nuts allow for a neat installation of the cover:



Major Tom to ground control

"Ground" is the key word here. After final assembly of the oil filter / adapter, the oil temperature / warning light sensor had no ground. So, the oil pressure showed a constant 10 bar and the "idiot light" did not come on. An update in the ground connection was necessary - but how? The sender unit only has 2 contact prongs, one for pressure and one for warning light. The M10x1 thread for attachment to the oil line is conical, so, no way to attach a ground strap...
The solution was to ground the housing itself!
Today shown a little different - In a short photo story:








 (forgive my booger welds)

 a little zinc spray to avoid corrosion

 Ground strap attached! The sender is fully functional again

Freitag, 17. April 2020

Peter Kramer's California Käfer Shop / Stage Fright

Recently I mentioned Peter Kramers "California Käfer Shop" in one of my posts. When he was still located in Dortmund, basically on a scrap yard, this guy had it all, one piece windows, Baja bug kits, cheap taiwanese chrome parts, performance exhausts - you name it. A good amount of my monthly wage in the late 80ies was regularly brought to his shop. I still see the guy from time to time on the Maikäfertreffen or selling Hot Wheels and neon signs in the Techno Classica Fair in Essen, but this shop was the only source for rad Cal look parts since the mid 80ies. Also he sold the American "Hot VW's and Dune Buggies" and "VW Trends" magazines for 5 DM instead of the 12 DM you could buy it for at the book store of the main train station in Essen.Well, he was - and probably is still - a special character, but also thanks to his engagement and his shop, I became the VW nut I am today - and since the mid 80ies!

Here is a key ring I still own, with  the image of his "promotion vehicle" at the time, which he later sold to Helge Ohmes, the famous VW Dragster Bug  "Stage Fright" - originally built in Bakersfield CA by Michael Irvin



The Spaghetti Incident

Yes, another album title, but here it is all about the relocation of the ignition coil and cables, to remove as many cables from visibility:
This lot of wires could be removed

The coil is relocated to the left side of the engine compartment. Almost all wires are invisible now. It will only become apparent after final assembly, but if you compare this to the "before" status, you get the idea: Especially around the oil cooler and coil area, all sorts of wires strewn around



electric fuel pump installation finalized

This is the final set up of the fuel pump:

The bulkhead cover, fuel pump, filter and fuel line as well as the electrical connections, all in their final position, ready to run!

Here is a view from below, the routing of the complete systemcan be seen here:

2 rubber damped clamps lead the fuel line into the perfect contour

Montag, 13. April 2020

old school cool!

With the mechanical fuel pump deleted, I had to cap off the mounting hole for it in the engine block.
I knew I had such a block off plate since years somewhere in my parts stash. I must have bought in the early 90ies in a shop, known to every VW nut in Germany at that time, Peter Kramer's California Käfer Shop located in Dortmund, later moved to Schwerte.

Here it is, a CB performance cover in the old style packaging:


It is a perfect match to the new breather housing: