EJ20G into 67 Bug

[surfbeetle]

Mooosman thank you. I did shorten the sump based on what I saw on Outfront's website. They said they still run the stock amount of oil and just use a higher mark on the dipstick. I had a friend shorten the sump and fear it may leak so I'll have to fill it the first time and see what happens.

I am still working on the wiring. I decided to add some relays and an additional fuse block. I have run wiring to the front for the fuel pump under the fuel tank as well as the wiring for the radiator fans. I'm hoping to get it running before the end of the year but I did say that last year so who knows.

[surfbeetle]

I'm done with the additional fuse blocks and relays. Also I read Thomas's thread over on the Samba, http://www.thesamba.com/vw/forum/viewto ... sc&start=0
It's a very good thread on a conversion, I like the way he's done the radiator and I think I'm going to use his design for the radiator mounting and air scoop. Some good photos of his conversion are here on page 10 http://www.thesamba.com/vw/forum/viewto ... &start=180

[surfbeetle]

Two steps forward, one step back... I bought some Airkewld rear brake lines for my rear discs. I went to install them and found that my rear axle seals were leaking behind the CB Performance caliper brackets on both sides. I contacted a friend who works at Mendeola and he set me straight on the install of the axle seal kit. I did one side and it looks like it's not leaking. I hope to get the other side done this weekend and install the brake line on that side as well.

Also found the radiator I want like Thomas's set up in the samba thread I linked above. It's a scirocco radiator and found set up. They're about the same price over at Speedway Motors and at Summit Racing.

[coolrydes]

Glad it worked Craig... I'll send you a invoice....

[surfbeetle]

Thanks again Kevin, I was going to message you on Facebook and let you know. I was hoping to do the other side tonight but I got busy, hopefully I'll get to it on Saturday.

[surfbeetle]

Today I put an axle seal kit on the right side, the left is still sealed, thanks to Kevin over at Mendeola for his help. The other thing I did today was to rebuild the Z-bar on the rear suspension with the Wolfsburg West kit. In the 25 years that I have had this car, I never fixed the Z-bar, now it should actually work as designed. I'll try to get some photos up tomorrow.

[surfbeetle]

Anyone know where to get a piece of 3 inch diameter U bend pipe? From outer edge of one opening to outer edge of the other opening, I need it to be 7 1/2 inches. I need it to go from the intercooler to the intake throttle body.

So far, what I have found is 10 inches in length like these: http://www.siliconeintakes.com/product_ ... c71ac9388c

I don't really care if it's a rubber piece or metal tubing. I just need to connect the intercooler where I have it mocked up.

[56SemaRag]

Anyone know where to get a piece of 3 inch diameter U bend pipe? From outer edge of one opening to outer edge of the other opening, I need it to be 7 1/2 inches. I need it to go from the intercooler to the intake throttle body.

So far, what I have found is 10 inches in length like these: http://www.siliconeintakes.com/product_ ... c71ac9388c

I don't really care if it's a rubber piece or metal tubing. I just need to connect the intercooler where I have it mocked up.

For rigid it's going to be difficult to find your exact dimensions. I found a 3" 180* with a 4" center line radius for you...which will put it at 7" from edge to edge. A small 1/2" section added in the middle should get you there if I got your dilemma correct. Other than that you might have to go with silicone. Good luck!

[surfbeetle]

Thanks a bunch. I think I can do 7 inches. At this point, I have mocked up the position of the intercooler above the throttle body and am using a cardboard box to hold it up about where I wanted. I believe that I can lose a 1/2 inch, or if that doesn't work I could cut it and use another connector or just weld in a 1/2 inch piece. I'm going to order one this week.

[surfbeetle]

Here's an update. Today I fabbed up mounts for the intercooler and bolted the intercooler above the intake manifold. I used some angle metal and bent/welded the ends, drilled holes and got it all in place. I have one last strap mount to make, I'll do that the next time I work on it. I also bought a 3" pipe 180° bend. The ends are too far apart to connect up the intercooler and throttle body so I have to cut and weld it, I wanted to get the intercooler positioned before I start modifying the 3" pipe. Also I installed the center pipe of the exhaust with new gaskets.
Here are some photos

intercoolerbracket.jpg

The bracket on the right rear side of the intercooler. I got it fabbed and in place. The paint will come later.

intercooler1.jpg

Here's a front shot of the intercooler, on the left of the photo you can also see the Outfront Motorsports block off plate for the IAC.

exhaustcenter1.jpg

The center piece of the exhaust didn't come with my engine, I had to order it from J-hot on ebay and gaskets from Outfront.

engineshot.jpg

It all fits under the decklid, yes it's still swingaxle. I even have the decklid spring in but my hinge mounts are loose so the decklid would not stay up with out a prop.

zbar1.jpg

Like posted last week, I rebuilt the z-bar. Should be interesting since my body is 1/2 inch or so raised right back there so I'm not sure how it will work. Also, I added some large washers I got from the struts I took off of my Nissan Armada. You can see those on the picture below.

zbar4.jpg

fuseblock.jpg

Here's some wiring under the backseat. I added some relays and fuse block for the fuel pump, the radiator fan and the ecu. The challenge is keeping the space under the backseat opposite the battery clear because I'm planning on putting the heater under there.

[Ghia Nut]

do you have a larger picture of the one looking through where the parcel tray used to be? Im wondering about some clearance issues.
Any reason you cut the rear parcel tray?

Im also doing a super similar setup with mine, not to thread jack you...

[surfbeetle]

Ghia Nut, is there something specific you are looking for? I will be back out there today. As for why I cut the parcel tray... Originally I was looking to go with a rear radiator, one from a Jeep Cherokee that was 11x30 inches in size. So I cut the parcel tray. In my current design of now going with a front radiator, I could have done things a bit differently. The intake could be flipped and the intercooler could be on top and the parcel tray left intact. There are several guys with front radiators and flipped intakes that have done it that way.

Looking at your engine, you have a water to air intercooler, mine was supposed to have that but did not come with it so I got mine from a 2004 WRX. If I had the air/water intercooler AND my parcel tray was cut, then I would probably mount the intercooler on top of the trans and then use a pump and have a mini radiator below the trans. There was a guy on Aussieveedubbers that did that. In my case, I figure that if it gets too hot for the intercooler, I can use some decklid standoffs and get more air on the intercooler.

Now that my parcel tray is cut, I have found that it's much more convenient to work on stuff through the opening rather than slither under the car so now I am going to figure out a way to make it removable. I still want to have a subwoofer behind the back seat and I need room for my intercooler to throttle body pipe so the parcel area will shrink a bit.

[Ghia Nut]

Im really interested in how you made brackets for the air to air intercooler and how it interfaces with the engine. The pictures are just small enough so I cant get any fine details of what you did.
Im also a little concerned about using my ej22t and how the turbo is done in the stock location. I am worried about the top of the turbo hitting the parcel tray. Your turbo setup is identical to mine, I just have the sohc. In your picture it looks like it would be a super snug fit with the parcel tray in place. Ive searched and searched for pictures but your picture is the only picture that I have found where I can see the reference between the turbo and the parcel tray. I understand about cutting the parcel tray, if my project ever gets off the ground, its going to be a shoe horn job for sure.

As for the AWIC... I dont even want to talk about how hard it was for me to find that at the right price much less available. I dug through nasioc forever and finally found a dead thread from 3 or 4 years ago that the guy never sold it and his wife wanted it gone so I snatched it up quick.

Im also very interested to see how or what you use to join the exit of the intercooler to the tb, as I will be tackling that next but will have to make provisions for my BOV as yours is nicely included on the intercooler.

Ill be watching this thread closely and reading back over it. I really like to see how people take this swap on and I learn so much from what people do. Awesome thread and project btw.

[surfbeetle]

I'll get some photos for you. My engine had the stock BOV which is right at the turbo in between the out of the turbo and the intake to the turbo. It's black and is attached to both plastic pieces there. When I spoke to Outfront last week, I asked which BOV should I use, he said that the WRX one on the intercooler is better so I have figure that plumbing out.

The intercooler brackets are pieces of angle about 6 inches long, I cut into the angle about one inch from the end and then bent it over using my vise and then welded up the slots to make a support. I then drilled hole and mounted them to various spots on the intake manifold. Of course a picture is worth a 1000 words, I'll get those in a bit.

[surfbeetle]

Here's some more photos. Today I made a pipe to connect the intercooler to the throttle body.

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It looks like the top of the turbo would barely clear the parcel shelf if I had it in place, but the linkage from the wastegate to the turbo would not, appears to be about an inch too tall.

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