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Re: Boksie 3.0 complete rebuild.

Subject: Re: Boksie 3.0 complete rebuild.
by kululadotgroen on 2011/6/23 14:35:35

Ok so the bridge plate has been made for the back of the head. Very happy with how it came out, nice round corners for allowing the water to flow easily. The plate is 25mm thick, and the cavity is 20mm deep, measuring up the inlet and outlet pipes volume wise it should allow the same of not more water to pass. Will also still flow the holes where the water is supposed to come out and go in as the edges are very sharp, not really conducive to good flow.

Marked out last night like 11:30 or so.

Milled out with a bull nose tool.

Also sunk the holes so that I could use normal capscrews, they are a but stronger and more reliable than those cheese head allen bolts.

My dad made me this here plug...

...for this here hole...

Fitted the motor today, for a moment I was panicking a bit when #4 tb was fouling on the brake booster. But quickly realised that when I let it rest on the mountings it moved away. Not enough though, so I cut another 10 or so millimeter from the zorst side mounting to lean it a bit more to that side, tb moved away some more, and now the bottom of the sump is actually level with the cross member, but you can clearly see the motor lean to the passenger side. Doesn't bother me, can only shift more weight to that side to improve the handling and balance anyway.

Intake side, looks good much more space to work on the alternator and starter than with the 16V.

Exhaust side, still lots of space left for a nice branch.

Clearance on the back of the head. Still have about 10mm left there, more than enough so it won't touch. Glad that I don;t have to panelbeat the firewall.

Clearance between the #4 tb and the booster. Going to ahve to get creative with the intake there, want to run ramtubes, but might have to angle them to make space.

Clearance to the radiator and fan, only need to trim the bottom water outlet pipe slightly so it'll fit, top one I'll need to get a slightly longer one, but everything lines up perfectly.

Bought a few things over the past week or two. New TP100 harness, new VW radiator and copper button clutch. When I bought the silvertop motor I organised with the guys to swap the flywheel with another silvertop that had a blacktop flywheel on it for some reason. Today I finally got hold of that too, and my dad sommer gave it a skim while he was at it.

New copper button and the blacktop flywheel. Lying on top of the new radiator's box.

On Saturday morning me and my brother got stuck in and stripped the boksie down. Took us about 4 hours to take everything but the dash out, that's needed to still operate the steering. I'll help Jackie take the suspension out tomorrow night, then I can sort that out while he's busy with the body. I also want to upgrade the front brakes while I'm at it.

Say goodbye to the red boksie, the colour will be a bit of a surprise... :wink:

Initially I was a bit scared to take the windscreen and back window out. well not so much the front, because that you can still buy regularly, but the last time the back window blew out, at past the maximum the clock can show :twisted:, I had to drive around without a back window for almost 4 months before I could find one again.

Underside is also very messy, that'll also be sorted out, never really was painted the last time around, they only blasted some black rubberising stuff all over. The broken gearbox seal and diff made a right mess of the underside as you can see.