|V6 Transplant Diary - January
Monday - 12 January
Well it's been quite a while since my last update, so I thought it was about time I updated my site / diary. I had actually been flat out at work at the end of last year hence no updates, and then had 4 weeks off over xmas in which I was just plain lazy
I can say my new surge tank set-up is working well. I am only using a cheap facet LP pump and it is surviving. At first it stop and I thought it was dead. Whilst performing a post-mortem on it, I found it had rust flakes / metal particles in it from the main fuel tank (probably dislodged when I drilled and welded the new fitting into the fuel tank). The insides of the facet pump is a magnet, so the metal particles stuck all over that and basically seized the magnet in position. I cleaned the metal bits off the magnet and now it works fine again. I then bought a LP fuel filter and fitted it before the facet pump to prevent the problem from occuring again. Other than that, no more fuel problems, no weird cut-outs.
Mid September I went to the VWDCQ Action Day car show; http://www.vwdcqinc.org.au/actionday2003results.html
Unfortunately I didn't get best Baja, even though many people told me they thought mine was the best. The trophy went to an unregistered show Baja that arrived and left on a trailer, and obviously hasn't been offroad. It had a V8 and looked cool from the rear, but the front still had superbug fenders on it which I thought looked kinda weird (see the pic in the above link).
Then in Mid November I went to the Gold Coast VW show and swap meet. It was going to be a tough show as there was only an offroad class, so I was up against many very clean buggies. Lucky for me the show was peoples choice, and a lot of people must like my car as I won favorite offroad! Cool! Although the big surprise was getting 2nd Place in the Car Stereo class, which was judged by some guys from Gold Coast Car Sound. I didn't think I would stand a chance, but the judges said they liked my installation. They said it was neat and a lot of work had gone into it. Cool again!
Lining up to get into the Gold Coast Show
My two trophies! Yeah!
My sound system for those that haven't seen it.
The second last thing I said in my last update (September) was "It's at the level where hopefully it will retain some reliability. I use it offroad in remote places, so I don't want things breaking."
Well funny I said that. At the end of November I was on the Annual Manx
Club Fraser Island Trip, and had my first loss of reliability. Pics of the
trip can be found here;
Well here's how my weekend went...
Update - Video can be
found here - Videos
After quite a bit of investigation I had decided that the radiator had died from salt water corrosion. I figure it was thin when I got it, and being on Fraser Island with all the salt water just pushed it over the edged. The whole front cut was covered in salt water corrosion when I bought it, it must've been from the boat trip from Japan. The radiator must have corroded through the final little bit Sunday night, when I was home but the car was still dirty / salty. Lucky I went home 1 day early.
My solution to the radiator problem was to just buy another one, but to paint it black for extra protection. I managed to find one for $150 in perfect condition, and painted it with VHT barrel paint. The paint doesn't seem to have had any negative effect on the cooling.
The clutch was something else entirely. I pulled the motor and this is what I found.
Those fingers don't look right!
That piece of lining at the top definitely isn't right.
Yep it's definitely broken!
After a bit of searching a most
clutch people seemed to agree with the VW guru Gene Berg who said
"What about the stock fabric type lining? - For many applications
this is fine, however when high RPM is achieved you often blow this lining
apart at the rivets".
quote:So basically, if I buy a late model 2.1lt syncro clutch (been told it's the strongest, although Sachs and Luk say it's the same as the other 228mm plates anyway) it should be able to handle at least 1.7 times the syncro's redline. So 1.7 x 5400 = 9180rpm. so it should be fine.
I also found a clutch facing material manufacturer that states the burst speed of it's linings are 12000rpm. I guess that reduces once you drill rivet holes through it, but still it seems ample.
I just kept thinking that the standard Mazda clutch is organic lined with nothing fancy and it survives just fine. So why shouldn't the VW clutch handle the same revs? I started leaning towards buying a good Sachs or Luk clutch plate as opposed to the no-name unit I had.
I wanted to keep the sprung center as I drive it as an everyday car in traffic and over obstacles offroad. The sprung center is there to eliminate weird driveline vibrations and harmonics. I have a 0.70:1 ratio 4th so driveline harmonics while highway cruising is something I want to reduce.
In the end I bought a new genuine 228mm sachs clutch
plate. The difference between it and my old one is quite noticable, and
after looking at the Sachs clutch it was clear it was the way to go.
I also dropped my pressure plate and flywheel down to "direct clutch" to have the pressure plate machined flat, and the assembly dynamically balanced. You can see from the old clutch the pressure plate wasn't quite flat. It was a slight (about 0.006" I think) concave shape that put the pressure on the outer 2/3 of the plate. It took a while to get the flywheel back as the clutch shops balancing machined died and I had to wait for it to be repaired.
So just before xmas I braved the heat (and man it was hot)
to go down to the shed and install the new clutch. Xmas eve it went on
it's first run, and I have been very impressed so far with the new
clutches performance. Let me just say, the Sachs clutch is smooth.
So all that drama took up a lot of time, and a bit of money. Unfortunately that meant my other plans for work on the car over xmas went down the drain. I had hoped to get the air-con installed, and possibly a new less restrictive exhaust built. But time and money wasn't on my side. All I managed to do was to install the air-con compressor on the motor and do some clearancing to the engine cage for it.
Over Jan 3-4 weekend I went up the beach again to double island point for the BLBVW / Manx Club beach trip. It was good fun and the car and clutch performed perfectly with no problems.
So still on my list of things to do is the air-con, if I can just work out how to squash it all under / in the dash...
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