Building the Ultimate Killer Bee!

thrown_hammer · Post by **thrown_hammer** » Sat Feb 03, 2007 3:54 pm

Before I slap this thing on I have a question. The heat riser ports are drilled out but only around 1/8". How big do they need to be to be effective?

SANDDUDE · Post by **SANDDUDE** » Sat Feb 03, 2007 4:10 pm

thrown_hammer wrote:Before I slap this thing on I have a question. The heat riser ports are drilled out but only around 1/8". How big do they need to be to be effective?

I would say "as big as possible" with out compromising the tubing side walls.

thrown_hammer · Post by **thrown_hammer** » Sat Feb 03, 2007 4:17 pm

Well alright. That I can do.

thrown_hammer · Post by **thrown_hammer** » Sun Feb 04, 2007 10:11 am

Well, a little problem. The header is on, but the "inverted V" muffler doesn't fit in my engine cage. It's a Tri-mil system with the two bolt flange. I think a stinger might clear. I left a message with Turboblue. That's who I got the system from and I think he may have a stinger sitting around. looks like I get to drive the X-terra to work Monday...

thrown_hammer · Post by **thrown_hammer** » Mon Feb 05, 2007 11:11 am

Made my own stinger at lunch. I picked up a flange and two feet of 2” OD exhaust pipe. I gad to grind an angle on the pipe so I could weld it into the flange at (hopefully) the correct angle to clear the cage.

I set a roll of duct tape on the header flange and drew a line perpendicular to the floor. Then when I set the roll of tape on the welding table I slanted the pipe over to the same angle. Billy Red all the way!

If I got it right I will put a slight bend towards the rear and clamp the SuperTrapp on.

Post by **Leatherneck** » Mon Feb 05, 2007 2:55 pm

Sounds like you have nailed it, do you have pictures to back up this momentous occasion?

thrown_hammer · Post by **thrown_hammer** » Mon Feb 05, 2007 3:04 pm

No pics yet. It looks kinda stupid at the moment. The Muffler shop gave me the flange and pipe for free so i may go back and let them cut it to length and bend it.

It's 4 degrees here. Car still runs kinda poopy. But I drove it across town and back and the intake didn't frost up so I guess it was worth it...

thrown_hammer · Post by **thrown_hammer** » Mon Mar 19, 2007 4:54 am

Update for the archives.

Put the old Tri-mill / Super trapp back on.

Put all new brakes, bearings, and seals on the front end. Replaced an axle seal on the rear, Also was missing a lug and noticed the drum was cracked. So I put a good used drum on the rear.

Got my hands on a proven dialed in Solex H30/31 carb. Stuck it on the car last week. Car runs perfect now. In the rain, when it’s cold, all the time. Pretty much unbelievable.

Moral of the story: If your VW runs like crap, it’s the carb. If you have a brand new carb, it’s the carb. If you have a brand new carb and rebuild it, it’s still the carb.

thrown_hammer · Post by **thrown_hammer** » Thu Mar 22, 2007 7:01 pm

New alternater put on tonight if anyone is keeping score. The old one was wobbly!

Also opened up the axle seal for the third time. On my second new seal. I am beginning to think maybe the axle seal was leaking because the PO put it in wrong and since I am putting mine in the way the old one came out I am also putting them in wrong. If this one leaks I may have to get some training....

thrown_hammer · Post by **thrown_hammer** » Tue Mar 27, 2007 4:23 am

Still have a weird “thunka thunka” when I turn. I am beginning to suspect the kingpin/linkpins are just plain worn out? I pulled the front drums and everything looks good. No witness marks from rubbing. I didn’t look at the wheel bearings though. Maybe I need to make sure they have enough grease. I packed them pretty good, but it’s an easy check.

On the good news side I put my second new axle seal in sometime last week and as of this AM no leaks! The first one leaked within a day so maybe this one will hold?

All in all the car is running really good. Other than a couple nagging little things all is well.

vw505 · Post by **vw505** » Tue Mar 27, 2007 1:13 pm

i always found that with the seals thay will leak alittle till you roll/drive the car, then mine alway stopped

thrown_hammer · Post by **thrown_hammer** » Tue Mar 27, 2007 3:27 pm

Both outer wheel bearings were a little light on the grease. Although I packed them very well the first time around. I repacked them, shoved grease the best I could into the inner bearings, greased the crap out of the inner seal race, and filled the space inbetween bearings with grease. I also filled the grease caps before I knocked them back on. I drove around town and the noise seemed to have stopped.

Still have no leaks from the axle seal. (knock on wood)

thrown_hammer · Post by **thrown_hammer** » Mon Apr 09, 2007 2:13 pm

Still no front end noise and the axle seal is still dry! Yeah!

Now I just need to put in the new king pins and link pins.

RyanB · Post by **RyanB** » Mon Apr 09, 2007 4:25 pm

Is it running correctly now bud?

thrown_hammer · Post by **thrown_hammer** » Mon Apr 09, 2007 6:50 pm

Runs almost perfect. Seems a little tiny bit rich but I am scared to mess with anything.

I actually enjoy driving the car now instead of gritting my teeth everytime i look at it.