FI Build-up - German Plenum/TB & MS-1

[Vee Dub Nut]

Hey everyone! I thought I'd share my progress on my EFI build on my '67 Beetle. The plan is to use the German plenum and throttle body with CB's end-castings for induction, and use MS-1 with extra code to run the injection and EDIS ignition. Long term plans include a turbo, but that's further down the road. I got all my parts through Mario at The Dub Shop, and I have to say he gave me EXCELLENT service. I would not hesitate to send anyone his direction if your needing parts. I ordered the kit because I knew that it would be easier to pull all of the parts together. My goal is to learn the basics of MS, but at the same time I didn't want to keep my car down too long while I tried to source all the needed items, so the ready to build kit really appealed to me.

Here is everything that I got through Mario. As upgrades to his basic kit, I ordered the optional CB end-castings with 24lb/hr injectors, and LC-1 wideband. In addition to this, since he knew I was planning on going with the relay board for wiring, he made me a relay cable (saved me $70 from buying on from DIY) and a wiring harness.



Now I have to brag on Mario some more, I was just expecting a bundle of wires for the harness, but he made me a custom harness with the ends terminated and wires grouped in woven loom and heat shrinked ends just because he was feeling generous. You don't find too many people like that. Here is the harness:



Here is the plenum, injectors, and end castings



The ECM and relay cable



Fuel rails



His info (shameless plug)

[Vee Dub Nut]

The first thing I did was trial fit the plenum (note - while the engine is out I'm replacing tin and some other odds and ends, so don't mind the mismached paint. Everything will be cleaned and painted before final install)



I mounted up the 36-1 wheel to my pulley, and made a VR mount out of some stainless I had lying around



I then put in the new hole for the throttle cable. The FI beetle's throttle cable is about 4 inches over from where the original throttle tube went.



Here you can see the difference in distance



Now I came out a little high on the back side of the shroud. I put a slight arc in my throttle tube and was able to get the end down where I needed it to clear the body.



Been running the orignal generator on the car for a long time, but decided to go ahead and bump up to an alternator to give me some extra juice. Figured with the MS and running my laptop on a DC inverter, I'd give the charging system a little bump.



Put my belt on, and found out I'll need just a little more trimming on my VR sensor mount.



That's all for now.. made good progress tonight

[Vee Dub Nut]

Lastly, the car its going in



The engine is a 1915cc.
AS41 case
Scat 69mm CW Crank (cast unfortunately, it will be replaced before any major boost)
Mahle 94's
MOFOCO Hydro cam (mild grind)
MOFOCO 042 heads - unported
Standard header w/hideaway muffler
Not a big HP machine, but a nice tourqey driver

[miniman82]

Hell yeah, good choice on the cam package. I have the parts for a MOFOCO hydraulic 2275 in the garage, can't wait to put it together!

[84 IM Flier]

VeeDubNut, I will be following your progress with interest. I'm rebuilding my Intermeccanica 356 Porsche replica and plan on switching from 44 Webers to fuel injection. I've looked at the DUBs kit and like the idea of going with a single throttle body, but I am worried that I'll lose too much hp compared to a dual throttle body kit, such as the one sold by CB. My engine is a 2010, with ported heads and a fairly aggressive cam.
Ron

[Vee Dub Nut]

Ok.. so I spent some time after work on the lathe tonight to turn down my distributor plug. I could have just spend $30 from boostengineering.com to get a plug already made, but whats the fun in that right? This didn't cost me anything but my time and a scrap piece of aluminum.

Here it the lathe


What I started with was a square piece of aluminum stock. I've already started to mill on it here.


Action shot


Got it round


Another action shot, cutting below the main shoulder


Once I got it turned down correct OD for the shoulder and the shaft, I then used the cut off tool to cut the o-ring grove


After that, I backed the cut off tool up to the top end to cut it off of the stock


After a little clean-up, its done!


Now I just need to figure out how to get a lathe in my garage My job has its perks!

[Vee Dub Nut]

VeeDubNut, I will be following your progress with interest. I'm rebuilding my Intermeccanica 356 Porsche replica and plan on switching from 44 Webers to fuel injection. I've looked at the DUBs kit and like the idea of going with a single throttle body, but I am worried that I'll lose too much hp compared to a dual throttle body kit, such as the one sold by CB. My engine is a 2010, with ported heads and a fairly aggressive cam.
Ron

I'll be sure to post up my experience as I go along and get it done. I've got a very mild engine (hydro cam and stock port heads), so I'm not too worried about choking off the engine. Eventually I plan to go to turbo, so this is the way that I wanted to configure the induction. I've had several sets of duals on this engine (which I could tell a huge change in top end between the dual ICTs, to the 40 Dells, to the 44 Webers), so I will pretty easily know if I get any major power changes in the engine from dropping down to a single throttle body. I honestly expect a little top end change, but nothing too major, but I'll find out. If you have any specific questions along the way, feel free to PM me.

[panel]

My first plug I just cut up and old distributor and drilled/tapped the top for a NPT fitting. Worked great.

[Vee Dub Nut]

My first plug I just cut up and old distributor and drilled/tapped the top for a NPT fitting. Worked great.

yea I thought about that, but playing with the lathe was too enticing

[MarioVelotta]

Nice Vee Dub Nut! Your bug is hella clean I might need to get a couple of those plugs from you You should make some extras!!

[Turbinepowered]

I wish I knew how to work a lathe...

I'll be doing something very similar, though I'll be going with KE-jetronic (CIS-E) and MJ for my DIS setup. I have a downdraft air meter and a nearly-complete set of Beetle FI parts (that I scored for the cost of shipping because the dude was interested in the project ). Thinking of maybe doing a small turbo at the same time, possibly a K03 or K03s since they're cheap and readily available.

[Vee Dub Nut]

Ok.. made a little more progress. Spent the weekend cleaning up the all the tin and doing some painting. Then this afternoon I started doing final fitting on all of the parts. Still need to get the intake runners put on and a few other odds and ends, but getting closer. Still got a ways to go yet, I haven't even started wiring the car yet, or running the new fuel line, etc, etc...

A few pics...





The right hand intake and fuel rail. I'll have a small pressure gauge sitting on top of the rail so I can see whats going on when I'm working on it.



Top view



The left hand rail and CLT sensor.. I had a heck of a time getting those injectors installed. They went into the rails fairly easily, but the lower end of the injector wouldn't push into the manifold until I started to crank down on the rail hold down bracket



and the EDIS wheel and sensor, and my fancy distributor plug



Hopefully after the holidays I can really get a jump on the rest of the car and get it finished

[Vee Dub Nut]

Nice Vee Dub Nut! Your bug is hella clean I might need to get a couple of those plugs from you You should make some extras!!

I thought about it, but I don't think I can really make them any cheaper than the ones over at boostengineering.com. It takes some time to get them finished off nice. Starting with round stock would make things go quicker, but it still takes a lot of time to get them to look pretty.

[Vee Dub Nut]

I wish I knew how to work a lathe...

I'll be doing something very similar, though I'll be going with KE-jetronic (CIS-E) and MJ for my DIS setup. I have a downdraft air meter and a nearly-complete set of Beetle FI parts (that I scored for the cost of shipping because the dude was interested in the project ). Thinking of maybe doing a small turbo at the same time, possibly a K03 or K03s since they're cheap and readily available.

Working a lathe is really not too difficult. This is only the third time I've used one, and the first time in about four years really.

Your project sounds cool.. eventually I plan to go turbo, but that in all reality is going to be a while. My plans now are to get this wrapped up soon so I can get some good tuning in before the Texas VW Classic in April, then baby is due in June so I'm sure things will be pretty hectic after that

[Turbinepowered]

Working a lathe is really not too difficult. This is only the third time I've used one, and the first time in about four years really.

Your project sounds cool.. eventually I plan to go turbo, but that in all reality is going to be a while. My plans now are to get this wrapped up soon so I can get some good tuning in before the Texas VW Classic in April, then baby is due in June so I'm sure things will be pretty hectic after that

There will definitely be a build thread when it begins, I can assure you.

My last experience with a lathe was the first and only time I have ever had to get stitches. The tool snapped away from me and gashed my arm open. Ten stitches later... Oddly enough it left no scar. Doc must have treated me perfectly, as I have scars all over my hands from less stupid stuff.

Oh, and tighten yer belt!