Converting T1 AS41 1600 to Type3...oil cooler?

[altxf4]

Have a 1600DP with a AS41 case from my old bug. We recently purchased a 71 Square back. I am trying to convert the bug engine to the T3 cooling.

So I got almost everything in place. 1&2 side is done, but the 3&4 side is having issues.

the oil cooler I was running as a T1 looks like it might have been a T3 or T4 cooler as it has the bung for the oil sender, but it has been plugged.
When I try to line up the holes for mounting the oil cooler hangs way over the cylinders and over the head to where it obstructs the intake port area. Also the mounting holes on this cooler are a lot smaller than what was used to mount the upright adapter.

This is my first T3, and I need help! Do I need a different or aftermarket oil cooler or is the AS41 T1 case not adaptable?


Thanks

[sinistervw]

OP is me as I couldn't remember this oooooooold login info!

[Marc]

Just how long is this cooler? I'm having a hard time envisioning how it occlude the intake ports.

Type III coolers (and for that matter the cooler itself - not the adapter - on doghouse Type I) use 6mm hardware rather than the 8mm of the adapter.
It's been done by drilling out the cooler, but the "right" way is to replace the 8mm stud in the case with a step-stud that's 8x1.25 on one end and 6x1.0 on the other; you'll also need to sleeve at least one of the 8mm holes in the case "ears" down to 6mm in order for the cooler to be securely indexed - if you omit this step the only thing centering the cooler will be the seals.

If the cooler is from a `70-up Type III it'll take 021 117 151A seals; if it's an earlier, 8mm-passage Type III cooler it'll require conversion seals to adapt to a 10mm-passage case - 111 198 029.

[sinistervw]

Thanks! It looks like the way were were holding the oil cooler made it seem longer than it was. Will go by the faster store and get some step studs, and see if they have any sleeves.

Still need to find a cooler that doesn't have the sender hole plugged up.

[Marc]

You can drill & tap the cooler you have, just apply air pressure to it during the process so any chips will blow out....wear eye protection