I'm new to the 411/2 world, but not the aircooled one. Actually I have a recently built 1302GS with all the goodies (2.1 t4 with porsche cooling, KW front struts, complete 944 rear suspension, urethane bushings, tarox 6 pots in front and vented 944 in rears etc.) but I have always wanted something bigger and more comfortable.
just bought a 412 Variant. My aim is to build it into a real grand turismo I can drive in any weather or distance, even for longer trips.This car has only 73k kms on it, but was in storage for 15+ years (partly outside), has no engine, the brakes are gone etc etc but the interior seems untouched .. If I start work on it, I would like to modernize it in the same time while keeping stock(ish) from outside. In my book this is GL is all about. But this time I have to keep in on a budget to make it roll ASAP, and no need for overkill/fancy solutions.
I have read most of the related topics here and found a lot of useful infos, but maybe it's better to open a new one instead of bringig back 10 old ones, hope you don't mind. The car is far away from me, so I'm not able to check or measure parts, but google is my friend.
For me a project starts with the brakes . I want to keep the stock MC, so the upgraded system should work fine with it. Like the idea of the BMW/Volvo route, too bad they are for solid rotors. Does anybody here have real life experiences with this swap? Is there any option to put vented rotors directly on the spindles? If so, maybe a Tarox caliper can be found. They work great on a bug with the stock MC, are compact and light (1,5kg each) which means less unsprung weight and fitment under 15" rims. But they cost $$$. As for the rear Walter's idea on the 944 swap seems more than enough / slightly overkill with solids on front. I read about somebody (Bill?) here putting golf rotors on the back, but the pictures are no more available. Any other ideas are well come.
I might be lucky with the suspension as I have access to the local KONI workshop. Google shows some Bilstein B6 struts specially for the 412, do you know if it's true? Regarding the springs everybody is talking about BMW/Volvo V70 ones, but which one exactly and how much do they lower/firmer the ride? My biggest fears are the bushings. I read some forum members tried to manufacture them, but don't know how it turned out, are they available for now?
Then comes the transmission. I have a Rancho 4 spd with longer 4th (0.89) in the bug and even with the torque of the T4 I feel the absence of a 5th gear every time I drive it (not on the motorway but in the twisties). Actually I have a 901 sideshifter in the garage, it seems similar in dimensions to the original unit and have the shaft on the bottom which is good. On the other hand these boxes are said to be sloppy and weak, especially in 1th. The 915/930 are out of the budget, so remains only the suby 5spd which is $$$ too. I guess the biggest problem with it the shaft is on the upper part..if going above the rear crossmember (good word here?) is there any space under the rear seats to join the original shift linkage? Do you know how func's bus tranny swap ended up?
The engine is something to decide before all the orhers. My goal is in the 140 hp ballpark. I admit I am a big beliver of the type4 engines since I put it in the bug, but can't find any infos about how efficient the pancake cooling is. Is it up to the job for a mild 2.0 t4? Costwise there is an other solution...I know it's a big no-no for the purists but the subaru swap is also very temptating..with an ej20 or ej25 in the back you have plenty of torque, heating and A/C as well...and in this case the suby tranny swap make sence too. Everything I did on the bug is reversible due to plug&play parts, but there is no way back if going watercooled. On the other hand it can give a whole new life to a car and can be put back on the road for long years.
Please feel free to share your ideas and experiences that can move forward this project. Thanks
something I was talking about, congrats 
