72 Beetle EJ22 Build

[72marinablue]

Hello all, I figured I would give back to this forum a bit since I have learned so much reading through all the threads on here. I am currently in the process of installing an ej22 motor from a 1993 Legacy into my bug, and just wanted to share some of the things that I have done to make it a clean install. Currently I have the wiring harness done, but not shortened and fitted to my car. I am in the process of fabricating the exhaust, and making changes to the engine that will be handy later. I will let the pictures speak for themselves.

Things I have knocked off the list

Wiring harness
Sump stock fuel tank
Run 3/8" fuel lines through the tunnel and into the engine compartment
Shortened oil sump and pickup tube
Reversed coolant manifold (will add pictures later)
Many more things to come

I was rear ended a couple years ago and it really messed the car up. I have most of the body back to where it needs to be, but getting it moving under its own power is my major motive at the moment.

[panel]

Great skills...........nice oil pan!

[Iguana]

Damn that is gunna be a lot of welding to avoid a few bends. Is there any reason u are going to that length ?

[72marinablue]

Damn that is gunna be a lot of welding to avoid a few bends. Is there any reason u are going to that length ?

Because its cool and fun and a new way for me to practice a different fabrication technique. One other reason is it allows me to make an even tighter bend than what you can buy in a mandrel bend, which means that the ground clearance will be exceptional, you cant really tell from the pictures.

I also have a tig welder and thoroughly enjoy using it. I can sit there for hours and run beads.

I know it doesn't make sense to everyone, but I like it and thats all that matters.

[Iguana]

Makes perfect sense I use the same justification myself on many things I do

[andk5591]

Very nice work - keep posting. Fuel tank idea is neat. I may consider going that route instead of an external surge tank. And agree on the exhaust.....have fun. I wont do that myself though - Way too much work....

[72marinablue]

About done with the fabrication work for my header. Waiting on a vband flange that will connect the header to the canister style muffler i plan on making. I want the exhaust to exit out the stock location. You can see the amount of clearance i will get with this setup now. Before I make the muffler portion I plan on doing a test fit of what i have so far.

[72marinablue]

Here is a picture of the reverse coolant manifold that I made. I have a lathe at work so I made up the segment and welded in as an extension. It lines up straight with the car and fits under the intake manifold nicely.

[Iguana]

Cool, did you consider pumping the sump capacity out a bit to get it even higher and more clearance ?

[72marinablue]

Cool, did you consider pumping the sump capacity out a bit to get it even higher and more clearance ?

I did consider it but decided on taking the easy route. I only lost about a 1/2 quart capacity and I know I could run either without that or 1/2 quart over. I can always buy another pan to modify later if I change my mind. I see you modified your thermostat housing, I am in the middle of doing that at the moment.

[Iguana]

Yeah I use a EJ20 Turbo housing so it points the right way

[rubenski]

Verry nice work, love the exhaust! Will look killer!

[dlamyle]

looking good! I miss the fabrication days. Fortunately I made a bunch of mistakes and was able to redo things again and again...In fact, I'm feeling inspired by your pie cut headers for my down pipe which I've done 3 or 4 times! Now I just need a few more bottles of argon

[72marinablue]

looking good! I miss the fabrication days. Fortunately I made a bunch of mistakes and was able to redo things again and again...In fact, I'm feeling inspired by your pie cut headers for my down pipe which I've done 3 or 4 times! Now I just need a few more bottles of argon

Im sure I am making some mistakes as well, but its all fun! Love your Ghia, over 300hp must be insane.

[72marinablue]

So I built this extension onto the thermostat housing, Its pretty stout but I am still unsure about it. Trying to make pulling the engine out very easy, and also not a huge fan of running a rubber tube by the exhaust header. Ill probably just run it until it cracks or gives me issues.



But I am happy because I did the first fit up of the engine in the car! The exhaust looks like it is going to work perfectly, I just have to figure out how I want to make the custom muffler. The tips will definitely be coming out of the stock location, and I am planning on making some sort of canister muffler. Its all a big experiment but thats what makes it fun!







My reversed coolant manifold is pointing just a tad high, so I will be adjusting that for better fit. On the plus side ground clearance looks great! Lower than before, but not crazy low.