'68 Westy and a K20a swap...I ain't right ;)

[RonW]

NICE! but we need video as proof

[supaninja]

Just be patient, I am very embarrassed by the rat nest of wires, I just rigged it all to get it running and it looks like it. I now have a greater appreciation for all you conversion pervs, holy crap was that a lot of work.

[supaninja]

Update- I have put about 300 miles on it so far, and a couple of issues are now appearant. First and foremost, the radiator placement is definitely not ideal, it runs very hot. Second my iat's are 180-200, but I haven't plumbed up any intake yet so that's a easy fix. The final issue is the stock pressure plate is just not up to the task with this heavy vehicle and a little power. Considering what I just did, this is no big deal, the list could be far worst.

I have a few ideas to cool it down: flush the coolant and run water only with some water wetter, add a motorcycle radiator/fan to heater core inlet and outlet and mount it in the belly, put a big scoop over the side scoop(s), and add a second AFCO radiator/SPAL fan combo on the other side of the engine bay. Or I could put my radiator on the front of my hurst bumper. I kind of like the discrete route.

Drive report: This motor effortlessly pushes the westy along, the power is linear and smooth as glass. Mario spend a lot of time helping me with the cranking and ASE and it shows, I just turn the key and it's idling nice and smooth. I DL'd the spark basemap from the aftermarket Honda management and that was perfect for my motor. I got some quality time VEALing the low speed stuff, I can be cruising and look over at the dashboard and I'll think my laptop locked up because every gauge is rock steady, I have to blip the throttle to make sure it's talking, lol. I really like the Bluetooth module, it is so nice not having any wires running all the across the bus. Once I get the temps handled, this is going to be one amazing driver.

[supaninja]

One more report, I have yet to get the tps to work so that's on the to do list, and the iac is toast so I'm going to ordering up a brand new one tonight, $160 ouch!

[supaninja]

Update time! All those pics are from this weekend...I got a whole lot of seat time in, whoohoo! I did a trifecta of cooling band-aides and it worked: propped the engine lid open with a tennis ball, replaced the antifreeze with Water Wetter and distilled water, and made a side scoop to ram air to force cooling. Before all that I could barely drive it over 40mph on a cool night with temps in the 230-235F range. Now I can cruise at 70mph and my temps are in the 210-215F range with ambient in the 85-89F range.

What brought this swap on was oil leaking of the OG motor and I'm happy to report that the Honda motor hasn't required a drop of oil in the almost 1000 miles that I have on it so far. Unfortunately everything is happy, I am getting a pathetic 12mpg while driving 65-70mph. I really don't think I can tune that out either since the stock tranny is geared so low, 70mph=4300 rpm. I also NEED a KEP stage 1 pressure plate, holy crap do I have to granny this thing up to speed to keep from slipping the clutch. Brakes and suspension are going to need a once over too, this thing is a death trap when it's up to full speed, it requires way too much attention to keep it on the road with cross winds. Other then all that it's a great driver and I heart the motor upgrade. Seems like the random people out there like it too, since I got lots and lots of thumbs up.

[gearheadgreg]

Sweet! You migght try spacing out the license plate and cutting a big hole behind it (with a pusher fan if need be) to exhaust hot air. Do you route cooling air from the passenger side air intake to the engine intake air? Might help keep intake temps down a touch - but since you're squirted you can probably datalog that.

Is your cooling fan(s) shrouded on the radiator? I know that makes a diff - esp on a small Scirocco rad without natural airflow...

[supaninja]

I still need to shroud the rad. I am thinking about cutting the center of the engine lid and welding in some perforated sheet so I can latch the engine lid. With the lid propped my IAT's are around 10F over ambient while moving.

[55superbeetle]

Awesome! Glad to hear you're working all the bugs out. I'm doing a suby swap in an early bay right now and I'm putting a scirocco radiator on either side, hope it works. Hope to see some engine pic's soon.

[supaninja]

I think page 3 has some engine pics. 2 Scirocco radiators with some bigger side scoops should work just fine, the scoop made a world of difference with my motor, a lot more then I expected.

[Steve Arndt]

Did you get the TPS working? It may be running in a limp mode (MPG).

[supaninja]

Is there a limp mode on MS3? I thought the TPS was just for flood clear and AE.

[Steve Arndt]

duh, I thought you kept stock engine management for a moment.

[supaninja]

No, kpro was tempting. I still need to hook up the variable length intake and the valve timing control so maybe I can tune it a little better still.

[supaninja]

Well shoot, I guess I have some updates. I was a little too optimistic of the stock 200mm VW clutch, it was almost undrivable on it.



So a KEP stg 2 later and I'm dragging my notch like what!







So in 65F ambient temps I'm not overheating, I still need to calibrate my coolant temp sensor (reads 20F high) but I got the settings on the fan to where it's actually switching on and off now.

Now the real work begins since this rig is actually drivable now. So on the list, not in any particular order:

Finish mounting the MS3 box, relay board, term strips, fan relays, wiring...
mount a second radiator/fan
hook up AC/heat
replace the non operating TPS and IAC
hook up the variable length intake and variable timing control (that's not VTEC)
make an intake for it
coat the exhaust
paint the engine cage

One more thing, I finally pieced together a dedicated MS laptop. I got it off ebay for less then a bill and just reinstalled the OS, so if it gets jacked I don't have to worry about my personal info getting compromised.

[Piledriver]

You should eventually be able to get ~20-ish MPG with that rig, although you should probably keep your eyes out for a 091 or even a 901 trans for some taller gears... Quite strong and fits in a bus as well.